Surgical Sagittal Blade Cartridge

Abstract

The surgical saw blade cartridge comprises a guide bar formed by three plates. The cartridge has a blade extending distally from the guide bar and having a blade head including a plurality of teeth. The guide bar may be configured to have opposing edges that define mounting features for orienting the guide bar within a mount of a surgical saw. One of the plates may be configured to define a reference feature configured to align and / or verify the orientation of the cartridge by a navigation system. A method of aligning the cartridge within a known coordinate system is disclosed. The method may include determining a deviation between a predicted position of the cartridge and an actual position of the cartridge based on the reference feature, and defining a hybrid position of the cartridge within the known coordinate system based on the deviation.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims the priority and all benefits of U.S. Provisional Patent Application No. 63 / 354,477, filed on June 22, 2022, and all of its contents are expressly incorporated herein.

Background Art

[0002] A sagittal saw blade is a surgical saw having a head that pivots about an axis perpendicular to the blade. PCT Publication No. WO2006 / 017066A2 / U.S. Patent No. 7,497,860 and PCT Publication No. WO2016 / 182981A2 / U.S. Patent No. 10,687,823 each disclose a sagittal saw blade cartridge, and the contents of each are incorporated herein. The sagittal saw blade cartridge comprises a fixed guide bar and a blade head. The guide bar is an elongate member that is releasably attached to a handpiece, which is a saw for operating the cartridge. The blade head is pivotally attached to the guide bar and has teeth that extend forward from the guide bar. One or more drive links extend from the blade head toward the proximal end of the guide bar. The drive links are reciprocated back and forth by a drive assembly inside the saw. By this reciprocation of the drive links, the blade head pivots back and forth. By this pivoting of the blade head, the tissue against which the blade head is pressed can be cut with the teeth. This type of cartridge may also be referred to as a tip - rocking saw blade cartridge.

[0003] The advantage of the sagittal blade cartridge is that the only pivoting part of the cartridge is the distally located blade head. By comparison, in a conventional sagittal saw blade, the blade pivots from its attachment point to the saw to which the blade is attached. In the case of the cartridge, during operation, it is less likely to vibrate in the hand of the surgeon holding the handpiece and / or the robotic arm. Also, it is common practice to use a cutting guide to properly position the sagittal saw blade relative to the tissue the blade is to cut. When a conventional blade operates, the surface of the cutting guide that defines the slot in which the blade is mounted wears significantly due to the rocking of the blade. In the case of the guide bar of the surgical sagittal blade cartridge, it moves minimally in this slot. Therefore, by using a cartridge instead of a conventional blade, abrasion of the material constituting the cutting guide from the guide is suppressed.

[0004] When a conventional sagittal blade or sagittal blade cartridge advances through bone, the blade head is exposed to resistance and / or curved, inclined, or contoured surfaces. This resistance can be significant when the depth of cut is 5 cm or more. The bone adjacent to the lower surface of the cartridge is often more resistant to cutting than the bone located directly above the cartridge. Similarly, due to the curvature, angle, and / or shape of the bone surface, the sagittal blade cartridge can deflect in a certain direction. The cartridge, like most mechanical devices, will advance along the path of least resistance when moving forward. Since the bone above the cartridge can be less resistant to cutting than the bone below the cartridge, the cartridge can flex upward from the desired cutting plane during advancement. This upward flexure or drift of the blade is known as skiving. Also, depending on the bone density and bone shape at the entry point of the device, the cartridge can flex below the cutting plane during advancement. This type of blade flexure or drift is known as diving.

[0005] Blade deflection or drift is undesirable regardless of its direction. This is because a sagittal saw blade cartridge is typically used to remove bone and make it possible to fit an artificial implant into the space previously occupied by the removed bone. The implant has a surface designed to be accurately installed against the complementary surface of the bone to which the implant is attached. If the surface of the cut bone is not in the desired shape, the result of the implant fitting procedure may not be optimal.

[0006] Theoretically, increasing the thickness of the guide bar can also enhance the rigidity of the surgical sagittal blade cartridge. Naturally, the slot of the cutting guide through which the cartridge is inserted tends to become relatively narrow. The height of this slot is often 1.5 mm or less. This height limitation restricts the thickness of the cartridge guide bar that can be inserted into this slot. Furthermore, when the thickness of the guide bar increases, correspondingly, the thickness of the cut formed by the cartridge also needs to increase. Also, when the thickness of the cut increases, the cartridge may produce a cut surface that does not have the desired planar smoothness. Therefore, increasing the thickness of the guide bar usually does not provide a feasible solution for suppressing the occurrence of cartridge deflection. In robotic applications, the thickness of the cutting guide is not a limiting factor, but increasing the thickness of the guide bar requires increasing the thickness of the blade tip, which may increase the amount of bone removed (increase the workload) and be undesirable in some cases. SUMMARY OF THE INVENTION

[0007] The present invention relates to a novel and useful surgical sagittal blade cartridge. This surgical sagittal blade cartridge includes a guide bar designed to resist deformation when subjected to non-uniform resistance.

[0008] The surgical sagittal blade cartridge of the present invention includes a guide bar formed with three plates. There is a first plate (upper plate) and a second plate (lower plate) opposite to the upper plate. Between the first plate and the second plate, there is a third plate (inner plate). The inner plate is formed to have a curved head. The curved head functions as a boss around which the blade head of the cartridge pivots.

[0009] In this summary, a series of concepts are introduced in a simplified form and will be detailed separately in the following detailed description. This summary is not intended to limit the scope of the subject matter of the claims, nor is it intended to identify the main or essential features of the subject matter of the claims.

[0010] In one aspect, a saw blade cartridge for use with a surgical instrument is disclosed. The saw blade cartridge includes a guide bar. The cartridge also includes a first plate and a second plate each having a distal portion and a proximal portion. The cartridge further includes an inner plate at least partially disposed between the first plate and the second plate and defining a pivot surface. The cartridge also includes a blade at least partially disposed between the first plate and the second plate. The cartridge also includes a blade body including a proximal end and a distal end. The cartridge also includes a blade head disposed at the distal end of the blade body and having teeth formed thereon, and the proximal end of the blade body abuts against the pivot surface. In this cartridge, the proximal portions of the first plate and the second plate each define an outer peripheral edge. Also, in this cartridge, a portion of the inner plate extends beyond the outer peripheral edge defined by at least one of the proximal portions of the first plate and the second plate.

[0011] In a second aspect, a saw blade cartridge for a surgical instrument is disclosed. The saw blade cartridge further includes a guide bar. The cartridge further includes a first plate and a second plate, each having a distal portion and a proximal portion. The cartridge further includes an inner plate disposed partially between the first plate and the second plate. In the cartridge, the guide bar defines a pivotal surface. The cartridge further includes a blade disposed at least partially between the first plate and the second plate. The cartridge further includes a blade body including a proximal end and a distal end. The cartridge further includes a blade head disposed at the distal end of the blade body and having teeth formed thereon, and the proximal end of the blade body abuts against the pivotal surface. In the cartridge, the proximal portions of the first plate and the second plate each define an outer peripheral edge. In the cartridge, a part of the inner plate extends beyond the outer peripheral edge defined by at least one of the proximal portions of the first plate and the second plate.

[0012] In a third aspect, a saw blade cartridge for a surgical instrument and a navigation system is disclosed. The saw blade cartridge includes a guide bar including a distal portion and a proximal portion. The cartridge includes a first plate. The cartridge includes a second plate. The cartridge includes an inner plate disposed between the first plate and the second plate. The cartridge includes a blade disposed at least partially between the first plate and the second plate and the guide bar. The cartridge includes a blade body including a proximal end that abuts against a pivotal surface defined by the guide bar, and a distal end. The cartridge includes a blade head disposed at the distal end of the blade body and having teeth formed thereon. The cartridge includes at least three landmarks disposed on an outer surface of one of the first plate or the second plate and defining a plane of the guide bar within a coordinate system of the navigation system.

[0013] In a fourth aspect, a saw blade cartridge for a surgical instrument and a navigation system is disclosed. The saw blade cartridge also includes a guide bar including a distal portion and a proximal portion. The guide bar may include a first plate, a second plate, and an inner plate that is partially disposed between the first plate and the second plate and defines a pivot surface. The cartridge also includes a blade that is at least partially disposed between the first plate and the second plate. The blade may include a blade body including a proximal end that abuts the pivot surface and a distal end, and a blade head disposed at the distal end of the blade body and having teeth formed thereon. The cartridge also includes at least three openings defined in one of the first plate or the second plate, the at least three openings providing access to an outer surface of the inner plate at respective positions of the at least three openings.

[0014] In a fifth aspect, a saw blade cartridge for a surgical instrument is disclosed. The saw blade cartridge also includes a guide bar including a distal end and a proximal end. The guide bar may include a first plate, a second plate, and an inner plate that is partially disposed between the first plate and the second plate and defines a pivot surface, and a recess may be defined at a proximal end of at least one of the first plate, the second plate, or the inner plate. The cartridge also includes a blade that is at least partially disposed between the first plate and the second plate. The blade may include a blade body including a proximal end that abuts the pivot surface and a distal end, and a blade head disposed at the distal end of the blade body and having teeth formed thereon.

[0015] In a sixth aspect, a surgical saw system is disclosed. The surgical saw system also includes a surgical device including a mount that defines a mounting surface, the mount extending above the attachment surface and disposed on both sides of the longitudinal axis of the mount, a first wall and a second wall that are tapered with respect to the longitudinal axis of the mount, and at least one tab disposed on each of the first wall and the second wall, each tab being disposed above the attachment surface and extending across the entire attachment surface. The system also includes a saw blade cartridge removably attachable to the mount of the surgical device. The saw blade cartridge may include a guide bar including a distal portion and a proximal portion. The guide bar may include a first plate, a second plate, and an inner plate partially disposed between the first plate and the second plate, wherein the proximal portions of each of the first plate and the second plate respectively define an outer peripheral edge, and a portion of the proximal portion of the inner plate extends beyond the outer peripheral edge defined by at least one of the proximal portions of the first plate and the second plate. Further, in this system, the first wall and the second wall respectively engage at least one outer peripheral edge of the first plate or the second plate to facilitate alignment of the saw blade cartridge along the longitudinal axis, and each of the at least one tab engages a surface of the portion of the proximal portion of the inner plate that extends beyond the outer peripheral edge defined by at least one of the proximal portions of the first plate and the second plate.

[0016] In a seventh aspect, a method is disclosed for verifying the position and / or orientation of a surgical saw blade by a navigation system. The method also includes the step of positioning an instrument including a first tracking device such that a distal end of the instrument is disposed within a first one of a plurality of openings and abuts a surface of an inner plate. The method also includes the step of repositioning the instrument such that the distal end of the instrument is disposed within a second one of the plurality of openings and abuts the surface of the inner plate. The method also includes the step of determining an actual position and an actual orientation of the surgical saw blade based at least on positions of the first and second openings identified using the instrument. The method also includes the step of determining a predicted position and a predicted orientation of the surgical saw blade based on predetermined geometric data corresponding to a relationship between attachment features of a surgical manipulator on a first or second plate of the surgical saw blade and positions of the plurality of openings. The method also includes the step of comparing predicted positions and predicted orientations of the plurality of openings with actual positions and actual orientations of the plurality of openings.

[0017] In an eighth aspect, a method is disclosed for verifying the position and / or orientation of a surgical saw blade within a known coordinate system defined by a navigation system. The method also includes operating the instrument such that a distal end of the instrument including a first tracking device contacts each of a plurality of markings on an outer surface of a guide bar. The method also includes repositioning the instrument such that the distal end of the instrument contacts one of the plurality of markings on the outer surface of the guide bar. The method also includes determining an actual position and an actual orientation of each of the markings within the known coordinate system based at least on the posture of the instrument when contacting each of the markings. The method also includes determining a predicted position and a predicted orientation of the markings within the known coordinate system based on predetermined geometric data. The method also includes comparing the predicted position and the predicted orientation of each of the plurality of markings with the actual position and the actual orientation of each of the plurality of markings. The method also includes assigning a corrected position based on a deviation between the predicted position and the predicted orientation of each of the plurality of markings based on the predetermined geometric data and the actual position. The method also includes defining a plane of the surgical saw blade within the known coordinate system based on the corrected position.

[0018] In a ninth aspect, a method of operating a saw blade by a navigation system is disclosed. The method also includes attaching a surgical saw blade to a surgical manipulator including a first tracking device. The method also includes contacting each of at least three landmarks on the surgical saw blade with a distal end of an instrument including a second tracking device. The method also includes tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system when the distal end of the instrument contacts each of at least three landmarks on the surgical saw blade, and defining an actual position of each of at least three landmarks with respect to a known coordinate system. The method also includes performing a mathematical fit of the actual position of each of at least three landmarks and the predicted position of each of at least three landmarks with respect to the known coordinate system. The method also includes determining a hybrid position within the known coordinate system based on a product of the mathematical fits for each of at least three landmarks. The method also includes defining a plane of the surgical saw blade based on the hybrid positions for each of at least three landmarks within the known coordinate system.

[0019] In a tenth aspect, a method is disclosed for registering a saw blade within a known coordinate system of a navigation system. The method also includes attaching a surgical saw blade to a surgical manipulator that includes a first tracking device. The method also includes operating the instrument such that a distal end of the instrument that includes a second tracking device passes through each of at least three openings and contacts an inner plate exposed by each of the openings. The method also includes tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system when the distal end of the surgical instrument contacts the inner plate through each of at least three openings on the surgical saw blade, and defining an actual position of each of the at least three openings relative to the first tracking device of the surgical manipulator. The method also includes defining an actual position of a portion of the inner plate exposed by each of the at least three openings within the known coordinate system based on the tracked position of the instrument when contacting the inner plate through each of the at least three openings. The method also includes comparing an expected position of a portion of the inner plate exposed by each of the at least three openings within the known coordinate system with the actual position of the portion of the inner plate exposed by each of the at least three openings within the known coordinate system. The method also includes modifying the position of a portion of the inner plate exposed by each of the at least three openings within the known coordinate system based on a deviation between the actual position and the expected position of the portion of the inner plate exposed by each of the at least three openings. The method also includes defining a plane of the surgical saw blade based on the modification of the position of a portion of the inner plate exposed by each of the at least three openings.

[0020] In an eleventh aspect, a method for aligning a saw blade within a known coordinate system of a navigation system is disclosed. The method also includes attaching a surgical saw blade to a surgical manipulator including a first tracking device. The method also includes contacting each of at least three fiducial features on the surgical saw blade with a distal end of a surgical instrument including a second tracking device. The method also includes tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system when the distal end of the surgical instrument contacts each of at least three fiducial features on the surgical saw blade, and defining the actual positions of each of at least three fiducial features relative to the first tracking device of the surgical manipulator. The method also includes performing a mathematical fit based on the actual positions of each of at least three fiducial features relative to the known coordinate system and the expected positions of each of at least three fiducial features. The method also includes determining a hybrid position of at least three fiducial features within the known coordinate system based on the mathematical fit. The method also includes defining a plane of the surgical saw blade based on the hybrid position of at least three fiducial features within the known coordinate system.

[0021] In a twelfth aspect, a method for controlling a handheld medical robotic system for use with a surgical saw blade is disclosed. The method also includes registering the surgical saw blade relative to a navigation system. The step of registering the surgical saw blade may include operating the instrument to define a plane of the surgical saw blade within a first coordinate system relative to a second tracking device coupled to the handheld medical robotic system by inserting a distal end of the instrument into each of a plurality of openings and contacting a surface of an inner plate at each position of the plurality of openings. The method also includes navigating the surgical saw blade based on the position and orientation of the second tracking device.

[0022] In a 13th aspect, a method of controlling a handheld medical robotic system for use with a surgical saw blade is disclosed. The method also includes the step of aligning the surgical saw blade with respect to a navigation system. The step of aligning the surgical saw blade may include operating the instrument to define a plane of the surgical saw blade within a first coordinate system with respect to a second tracking device coupled to the handheld medical robotic system by contacting a surface of a guide bar using a distal end of the instrument that includes a first tracking device and tracing optical markings extending between two fiducial features. The method also includes the step of navigating the surgical saw blade based on the position and orientation of the second tracking device.

[0023] In a 14th aspect, a surgical saw system is disclosed. The surgical saw system also includes a surgical device having a mount that defines a mounting surface. The system also includes a first wall and a second wall that extend above the mounting surface and are disposed on both sides of the longitudinal axis of the mount. The system also has the first wall and the second wall, and the first wall and the second wall each have a proximal portion oriented at a first internal taper angle with respect to the longitudinal axis of the mount and a distal portion oriented at a second internal taper angle with respect to the longitudinal axis of the mount. In this system, the second internal taper angle is not the first taper and is greater than the first internal taper angle with respect to the longitudinal axis of the mount. The system also includes at least one tab disposed on each of the first wall and the second wall, each tab being disposed above the mounting surface and extending across the entire mounting surface. The system also includes a saw blade cartridge removably attachable to the mount of the surgical device. The system also includes a guide bar including a distal portion and a proximal portion. The system also includes a first plate. The system also includes a second plate. The system also includes an inner plate partially disposed between the first plate and the second plate. In this system, one of the first plate and the second plate defines an outer edge of the proximal portion of the guide bar. In this system, the proximal portions of the first wall and the second wall each engage the outer edge of the proximal portion of the guide bar to facilitate alignment of the saw blade cartridge along the longitudinal axis. In this system, the distal portions of the walls are spaced from the outer edge of the proximal portion of the guide bar. In this system, the lower surface of each of the at least one tab is disposed across the entire upper surface of the inner plate. In some of the above-described embodiments, the guide bar may further define a longitudinal axis extending between the distal portion and the proximal portion of the guide bar.The outer circumference of the proximal portion of the guide bar defines a first taper angle with respect to the longitudinal axis between a first point and a second point on the outer circumference, and defines a second taper angle with respect to the longitudinal axis between the second point and a third point on the outer circumference. The first point is closer to the proximal end of the cartridge than the third point, and the second point is disposed between the first point and the third point.

[0024] In some of the above embodiments, the outer edge of the proximal portion of the guide bar may define a third taper angle with respect to the longitudinal axis.

[0025] In some of the above embodiments, the pivot surface may include an arcuate surface, and the proximal end of the blade body defines a recess that abuts against the pivot surface, so that the blade body is configured to pivot around the pivot surface defined by the inner plate during operation.

[0026] In some of the above embodiments, at least one of the plates may define a reference feature configured to facilitate determination of the position and / or orientation of the surgical saw blade cartridge within a known coordinate system of the navigation system.

[0027] In some of the above embodiments, the reference feature is selected from the group including optical markings, depressions, or openings, includes a plurality of laser markings, and at least one of the plurality of laser markings is disposed on both sides of the longitudinal axis of the surgical blade cartridge.

[0028] In some of the above embodiments, at least one of the first plate or the second plate is shaped to provide access to the reference feature of the inner plate, and the reference features are respectively disposed on the surface of the inner plate exposed by the opening in one of the outer plates.

[0029] In some of the above-described embodiments, the positions of the marks and / or reference features defined on the guide bar may be configured to identify the saw blade cartridge (including one or more characteristics of the saw blade cartridge) to the navigation system, and the characteristics include at least one of the type of blade, the blade thickness of the blade head, the tooth configuration of the blade head, the length of the guide bar, and / or the width of the guide bar.

[0030] In some of the above-described embodiments, the surgical manipulator and / or the surgical instrument is one of a hand-held tool, a robotic arm, or a hand-held robot.

[0031] In some of the above-described embodiments, the guide bar is further shaped such that a part of the inner plate is exposed by one of the first outer plate and the second outer plate, and the exposed part is configured to engage with the mount of the surgical manipulator.

[0032] In some of the above-described embodiments, the proximal portion of the surgical saw blade cartridge may define an outer periphery, and a part of the outer periphery may be a contact point that removably engages with the surgical manipulator to assist in aligning the saw blade cartridge with the surgical instrument.

[0033] In some of the above-described embodiments, the blade head may define one or more openings or notches that allow for the discharge of foreign matter and / or one or more openings or notches used as reference points during the manufacture of the blade.

[0034] In a 15th aspect, a surgical saw system is disclosed. The surgical saw system also includes a surgical device including a mount that defines a mounting surface. The mount extends above the attachment surface and is disposed on both sides of the longitudinal axis of the mount. The mount includes a first wall and a second wall that are tapered with respect to the longitudinal axis of the mount, and at least one tab disposed on each of the first wall and the second wall, each tab being disposed above the attachment surface and extending across the entire attachment surface. The system also includes a saw blade cartridge removably attachable to the mount of the surgical device. The system also includes a guide bar including a distal portion and a proximal portion. The system also includes a first plate and a second plate, at least one of which defines a first outer edge of the proximal portion of the guide bar. The system also includes an inner plate partially disposed between the first plate and the second plate and defining a pivot surface and a second outer edge of a portion of the proximal portion of the guide bar. In this system, the second outer edge of the inner plate extends beyond the first outer edge defined by the first plate and engages the first wall and the second wall of the surgical device to assist in aligning the saw blade cartridge within the mount of the surgical device.

[0035] In a 16th aspect, a saw blade cartridge for use with a surgical device is disclosed. The saw blade cartridge also includes a guide bar including a distal portion and a proximal portion. The cartridge also includes a first plate. The cartridge also includes a second plate disposed adjacent to the first plate and defining a pivotal surface. The cartridge also includes a blade extending distally from the distal portion of the guide bar. The cartridge also includes a blade body including a proximal end and a distal end. The cartridge also includes a blade head disposed at the distal end of the blade body and having teeth formed thereon, and the proximal end of the blade body abuts against the pivotal surface. In the cartridge, the proximal portion defines a proximal end. In the cartridge, the first plate defines a first outer edge. In the cartridge, the second plate defines a second outer edge extending beyond the first outer edge defined by the first plate, and the second outer edge is tapered outwardly and moves distally from the proximal end of the proximal portion to the distal end of the proximal portion so as to assist in aligning the saw blade cartridge with the surgical device, thereby defining the second outer edge.

[0036] In a 17th aspect, a saw blade cartridge for use with a surgical device is disclosed. The saw blade cartridge also includes a guide bar including a distal portion and a proximal portion. The cartridge also includes a first plate defining a first outer edge of the proximal portion. The cartridge also includes a second plate disposed adjacent to the first plate and defining a pivotal surface and a second outer edge of the proximal portion of the guide bar. In the cartridge, the second outer edge extends beyond the first outer edge defined by the first plate and is configured to engage with the surgical device so as to assist in aligning the saw blade cartridge with the surgical device. The cartridge also includes a blade extending distally from the distal portion of the guide bar. The cartridge also includes a blade body including a proximal end configured to abut against the pivotal surface.

[0037] In an eighteenth aspect, a saw blade cartridge for use with a surgical instrument guided by a navigation system is disclosed. The saw blade cartridge also includes a guide bar having a distal portion and a proximal portion. The cartridge also includes a first plate that defines a first opening. The cartridge also includes a second plate that defines a second opening. The cartridge also includes an inner plate that is partially disposed between the first plate and the second plate and that defines a pivotal surface. In this cartridge, the first opening and the second opening are configured to facilitate determination of the position and / or orientation of the guide bar by the navigation system. The cartridge also includes a blade that extends distally from the distal portion of the guide bar. The cartridge also includes a blade body that includes a proximal end configured to abut the pivotal surface. In this cartridge, the proximal portion defines the proximal end. In this cartridge, the first plate and the second plate are arranged such that the first opening and the second opening are concentrically aligned.

[0038] In a 19th aspect, a saw blade cartridge is disclosed for use with a surgical instrument that includes a tracker that is identifiable by / associated with a navigation system. The saw blade cartridge also includes a guide bar having a distal portion and a proximal portion. The guide bar may include a first plate that defines a first fiducial feature at the distal portion and a second fiducial feature at the proximal portion, a second plate that defines a third fiducial feature at the distal portion and a fourth fiducial feature at the proximal portion, and an inner plate that is disposed at least partially between the first plate and the second plate, and the combination of fiducial features may be used for aligning the saw blade cartridge within a known coordinate system defined by the navigation system relative to the tracker of the surgical instrument. The cartridge also includes a blade that is disposed at least partially between the first plate and the second plate. The cartridge also includes a blade body that includes a proximal end and a distal end. The cartridge also includes a blade head that is disposed at the distal end of the blade body and has teeth formed thereon.

[0039] In a 20th aspect, a surgical saw assembly for use with a navigation system is disclosed. The surgical saw assembly also comprises a surgical instrument / device including an instrument reference feature. The assembly also comprises a tracker disposed on the surgical instrument and / or a tracker associated with the navigation system, which is identifiable by the navigation system. The assembly also comprises a saw blade cartridge removably attachable to the surgical device. The saw blade cartridge may comprise a guide bar having a distal portion and a proximal portion. The guide bar may comprise a first plate defining a first reference feature at the distal portion and a second reference feature at the proximal portion, a second plate defining a third reference feature at the distal portion and a fourth reference feature at the proximal portion, and an inner plate at least partially disposed between the first plate and the second plate and defining a pivoting surface. Also, in this assembly, the combination of features can be used to facilitate alignment of the saw blade cartridge within a known coordinate system defined by the navigation system for the tracker of the surgical device, and the blade extends from the distal portion of the guide bar.

[0040] In a 21st aspect, a method of aligning a saw blade within a known coordinate system of a navigation system is disclosed. The method also comprises attaching a surgical saw blade to a surgical manipulator including a first tracking device. The method also comprises contacting at least three reference features on the surgical saw blade with the distal end of a surgical instrument including a second tracking device. The method also comprises tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system when the distal end of the surgical instrument contacts each of the at least three reference features on the surgical saw blade, to define the actual positions of each of the at least three reference features relative to the first tracking device of the surgical manipulator. The method also comprises defining a plane of the surgical saw blade based on the actual positions of the at least three reference features within the known coordinate system.

[0041] In a 22nd aspect, a method for aligning a saw blade within a known coordinate system of a navigation system is disclosed. The method also includes attaching a surgical saw blade to a surgical manipulator that includes a first tracking device. The method also includes contacting at least two reference features on a first surface of the surgical saw blade with a distal end of a surgical instrument that includes a second tracking device. The method also includes contacting at least two reference features on a second surface of the surgical saw blade with the distal end of the surgical instrument. The method also includes tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system when the distal end of the surgical instrument contacts the reference features on the first surface and the second surface of the surgical saw blade, respectively, to define the actual positions of the reference features of the first surface and the second surface relative to the first tracking device of the surgical manipulator. The method also includes comparing the actual positions of the reference features in the known coordinate system and the position of a manipulator reference feature to confirm whether the surgical saw blade is properly attached to the surgical manipulator.

[0042] In a 23rd aspect, a method for aligning a saw blade within a known coordinate system of a navigation system is disclosed. The method also includes the step of attaching a surgical saw blade cartridge to a surgical manipulator, the surgical saw blade cartridge including a guide bar having a first plate disposed adjacent to a second plate, and a blade at least partially disposed between the first plate and the second plate and extending from a distal end of the guide bar, the surgical manipulator including a first tracking device. The method also includes the step of contacting at least two respective fiducial features on the first plate of the guide bar with a distal end of a surgical instrument including a second tracking device. The method also includes the step of contacting at least two respective fiducial features on the second plate of the guide bar with a distal end of the surgical instrument, each fiducial feature of the first plate being concentric with one of the fiducial features of the second plate. The method also includes the step of tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system when the distal end of the surgical instrument contacts the respective fiducial features on the first plate and the second plate of the surgical saw blade cartridge, to define the actual positions of the respective fiducial features of the first plate and the second plate relative to the first tracking device of the surgical manipulator. The method also includes the step of determining the thickness of the cartridge based on the actual positions of the fiducial features on the first plate and the second plate. The method also includes the step of providing an indication to the user based on the determined thickness of the cartridge.

[0043] In a 24th aspect, a method of aligning a saw blade within a known coordinate system of a navigation system is disclosed. The method also includes attaching a surgical saw blade to a surgical manipulator that includes a first tracking device. The method also includes contacting at least two fiducial features on a first surface of the surgical saw blade, respectively, with a distal end of a surgical instrument that includes a second tracking device. The method also includes contacting at least two fiducial features on a second surface of the surgical saw blade, respectively, with the distal end of the surgical instrument. The method also includes contacting at least one fiducial feature on the surgical manipulator. The method also includes tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system when the distal end of the surgical instrument contacts the fiducial features on the surgical saw blade and the surgical manipulator, respectively, to define the actual positions of the fiducial features of the surgical saw blade relative to the fiducial feature of the surgical manipulator. The method also includes defining a hybrid position of each of at least one fiducial feature of the surgical manipulator by performing a mathematical fit between the actual position of each of the fiducial features of the surgical saw blade and at least one fiducial feature of the surgical manipulator.

[0044] In a 25th aspect, a method of aligning a surgical saw blade within a known coordinate system of a navigation system is disclosed. The method also includes attaching the surgical saw blade to a surgical manipulator that includes a first tracking device. The method also includes contacting at least two fiducial features, respectively, on a first surface of the surgical saw blade with a distal end of a surgical instrument that includes a second tracking device. The method also includes contacting at least two fiducial features, respectively, on a second surface of the surgical saw blade with the distal end of the surgical instrument. The method also includes tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system when the distal end of the surgical instrument contacts the fiducial features on the first surface and the second surface of the surgical saw blade, respectively, to define the actual positions of the fiducial features of the first surface and the second surface relative to the first tracking device of the surgical manipulator. The method also includes defining the position and / or orientation of the surgical saw blade within the known coordinate system in one or more degrees of freedom based on a mathematical fit of the positions of at least two fiducial features of each of the first surface and the second surface.

[0045] In a 26th aspect, a method for aligning a surgical saw assembly within a known coordinate system of a navigation system is disclosed. The method also includes attaching a surgical saw blade to a surgical manipulator including a first tracking device. The method also includes contacting at least two fiducial features on a first surface of the surgical saw blade with a distal end of a surgical instrument including a second tracking device. The method also includes contacting at least two fiducial features on a second surface of the surgical saw blade with the distal end of the surgical instrument. The method also includes contacting a manipulator fiducial feature defined on the surgical manipulator with the distal end of the surgical instrument. The method also includes tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system when the distal end of the surgical instrument contacts the fiducial features on the first surface and the second surface of the surgical saw blade, respectively, to define the actual positions of the fiducial features of the first surface and the second surface and the manipulator fiducial feature relative to the first tracking device of the surgical manipulator. The method also includes defining a hybrid position of the manipulator fiducial feature within the known coordinate system based on a comparison of the actual positions of the fiducial features of the first surface and the second surface relative to the manipulator fiducial feature. The method also includes defining the position and / or orientation of the surgical saw assembly within the known coordinate system in at least one degree of freedom based on a mathematical fit of the positions of at least two fiducial features of each of the first surface and the second surface and the hybrid position of the manipulator fiducial feature.

[0046] In a 27th aspect, a method of aligning a saw assembly within a known coordinate system of a navigation system is disclosed. The method also includes attaching a surgical saw blade to a surgical manipulator including a first tracking device. The method also includes contacting at least two reference features each on a first surface of the surgical saw blade with a distal end of a surgical instrument including a second tracking device. The method also includes contacting at least two reference features each on a second surface of the surgical saw blade with the distal end of the surgical instrument. The method also includes contacting a manipulator reference feature defined on the surgical manipulator with the distal end of the surgical instrument. The method also includes tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system when the distal end of the surgical instrument contacts the reference features on the first surface and the second surface of the surgical saw blade, respectively, to define the actual positions of the reference features of the first surface and the second surface and the manipulator reference feature with respect to the first tracking device of the surgical manipulator. The method also includes applying a first mathematical fit to the actual positions of the reference features of the first surface and the second surface and the manipulator reference feature to each other. The method also includes defining a hybrid position of the manipulator reference feature based on the first mathematical fit. The method also includes applying a second mathematical fit to the actual positions of the reference features of the first surface and the second surface and the hybrid position of the manipulator reference feature to each other. The method also includes defining the position and / or orientation of the surgical saw assembly within the known coordinate system in one or more degrees of freedom based on the second mathematical fit.

[0047] In a 28th aspect, a method for verifying the attachment of a surgical saw blade to a surgical manipulator is disclosed. The method also includes attaching a surgical saw blade to a surgical manipulator that includes a first tracking device. The method also includes contacting at least two fiducial features on a first surface of the surgical saw blade with a distal end of a surgical instrument that includes a second tracking device. The method also includes contacting a manipulator fiducial feature defined on the surgical manipulator with the distal end of the surgical instrument. The method also includes applying a mathematical fit to the actual positions of the fiducial features of the first surface and the manipulator fiducial feature relative to each other. The method also includes comparing the output of the mathematical fit to a threshold value, wherein the output of the mathematical fit relative to the threshold value indicates whether the surgical saw blade is properly attached to the surgical manipulator.

[0048] In a 29th aspect, a method is disclosed for verifying the alignment of a surgical saw blade within a known coordinate system of a navigation system. The method also includes attaching the surgical saw blade to a surgical manipulator that includes a first tracking device. The method also includes contacting a first fiducial feature disposed proximally on a first plate of the surgical saw blade and a second fiducial feature disposed distally on the first plate with a distal end of a surgical instrument that includes a second tracking device. The method also includes contacting a third fiducial feature disposed proximally on a second plate of the surgical saw blade and a fourth fiducial feature disposed distally on the second plate with the distal end of the surgical instrument. The method also includes defining a first blade thickness based on a comparison of the positions of the first fiducial feature of the first plate and the third fiducial feature of the second plate. The method also includes defining a second blade thickness based on a comparison of the positions of the second fiducial feature of the first plate and the fourth fiducial feature of the second plate. The method also includes calculating a deviation between the first blade thickness and the second blade thickness. In the method, the deviation between the first blade thickness and the second blade thickness indicates a deflecting of a distal portion of the first plate and / or the second plate when contacting the second fiducial feature or the fourth fiducial feature.

[0049] One or more embodiments of the above aspect may optionally include one or more of the following features. In this method, the step of defining the hybrid position of at least one reference feature of the surgical manipulator within a known coordinate system based on a mathematical fit is to ensure that the hybrid position of each reference feature differs from the actual position by only one degree of freedom. The step of defining the hybrid position of at least one reference feature of the surgical manipulator within a known coordinate system based on a mathematical fit is to move the actual position of each at least one reference feature of the surgical manipulator by only one degree of freedom. This method may include a step of comparing the actual position of at least one reference feature of the manipulator with the actual position of each reference feature of the surgical saw blade, and a step of determining whether the surgical saw blade is properly attached to the surgical manipulator based on the deviation between the actual position of at least one reference feature of the manipulator and the actual position of each reference feature of the surgical saw blade being within an allowable threshold / range. This method may also include a step of rejecting the alignment of the surgical saw blade within the known coordinate system of the navigation system based on the deviation between the actual position of at least one reference feature of the manipulator and the actual position of each reference feature of the surgical saw blade being within an allowable threshold / range. This method may include a step of comparing the hybrid position of at least one reference feature of the manipulator with the actual position of each reference feature of the surgical saw blade, and a step of determining whether the surgical saw blade is properly attached to the surgical manipulator based on the deviation between the hybrid position of at least one reference feature of the manipulator and the actual position of each reference feature of the surgical saw blade being within an allowable threshold / range. This method may also include a step of rejecting the alignment of the surgical saw blade within the known coordinate system of the navigation system based on the deviation between the hybrid position of at least one reference feature of the manipulator and the actual position of each reference feature of the surgical saw blade being within an allowable threshold / range.The allowable threshold for the deviation between the hybrid position of at least one reference feature of the manipulator and the actual positions of the reference features of the surgical saw blade is plus or minus 1 millimeter (±1 mm).

[0050] Also, one or more embodiments of the above aspects may optionally include one or more of the following features. This method may include a step of bringing a manipulator reference feature defined on a surgical manipulator into contact with the distal end of a surgical instrument, and a step of defining a hybrid position of the manipulator reference feature within a known coordinate system based on a comparison of the actual positions of the reference features of the first surface and the second surface with respect to the manipulator reference feature. Further, the tool center point may be defined based on the mathematical fitting of the positions of at least two reference features of each of the first surface and the second surface and the hybrid position of the manipulator reference feature. The step of defining the position and / or orientation of the surgical saw blade within a known coordinate system in one or more degrees of freedom may include defining the position and / or orientation of the surgical saw blade within a known coordinate system in up to six degrees of freedom.

[0051] Any of the above aspects can be combined in whole or in part. Any features of the above aspects can be combined in whole or in part. Any of the above embodiments regarding any aspect can be combined with any other aspect. Any of the above embodiments can be combined with any other embodiment, regardless of whether they are the same embodiment or different embodiments.

[0052] The present invention is shown in detail in the claims. The above and other features and advantages of the present invention will be understood from the following detailed description in conjunction with the accompanying drawings.

Brief Description of the Drawings

[0053]

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DETAILED DESCRIPTION OF THE INVENTION

[0054] Referring to FIG. 1, a surgical system 10 is shown. In the illustrated surgical system 10, an artificial knee joint surgery is being performed on a patient 12 to enable the patient 12 to receive an artificial knee joint implant IM by removing a portion of the femur F and tibia T of the patient 12. The surgical system 10 may be used to perform other types of surgical procedures including surgeries involving hard / soft tissue removal or other forms of treatment. For example, treatments may include tissue cutting, tissue coagulation, tissue ablation, tissue stapling, tissue suturing, etc. In some examples, the surgical procedure may include knee surgery, hip surgery, shoulder surgery, spinal surgery, and / or ankle surgery, and may also include removal of tissue to be replaced with a surgical implant such as a knee implant, a hip implant, a shoulder implant, a spinal implant, and / or an ankle implant. The surgical system 10 and techniques disclosed herein may be used to perform other surgeries regardless of whether they are surgical, and may also be used in industrial or other applications where the surgical system is utilized.

[0055] Referring to FIGS. 1 and 2, surgical system 10 includes a surgical manipulator 14. The surgical manipulator may include a handheld instrument, a handheld medical robotic system, a surgical robot, or the like. The surgical manipulator 14 may also be referred to as a surgical instrument. Exemplary handheld robotic instruments are shown in PCT / US2020 / 042128, PCT / US2022 / 013108, PCT / US2022 / 013115, and PCT / US2022 / 054115, the entire contents of all of which are incorporated herein. Exemplary non-robotic instruments are shown in U.S. Patent No. 7,704,254, the entire contents of which are also incorporated herein. In some examples, the user manually holds and supports the surgical instrument 14 (as shown in FIG. 1). In some examples, the user may manually hold the surgical instrument 14 that is at least partially or fully supported by an auxiliary device such as a passive arm (e.g., a link mechanism arm with a locking joint, a weight balance arm), an active arm, and / or the like. As best shown in FIGS. 1 and 6A, the surgical instrument 14 includes a tool platform 16.

[0056] The surgical instrument 14 may be freely moved and supported by the user without the assistance of a guide arm, and for example, may be configured such that the weight of the tool is supported only by the user's hand during surgery by being held by a human user who physically removes material. In other words, the surgical instrument 14 may be configured to be held such that the user's hand supports the instrument 14 against gravity. The weight of the surgical instrument 14 may be 8 pounds or less, 6 pounds or less, 5 pounds or less, or 3 pounds or less. The surgical instrument 14 may have a weight corresponding to ANSI / AAMI HE75:2009. Also, the instrument 14 includes a tool mount 18 for receiving the tool 20. In some examples, when the tool 20 is a saw blade 110, the tool mount 18 may also be referred to as a blade mount.

[0057] In certain operations of the surgical system 10 detailed below, the tool 20 is coupled to the tool mount 18 and interacts with the biological structure. The tool 20 may also be referred to as an end effector. The tool 20 may be removable from the tool mount 18 so that a new / different tool 20 can be attached as needed. Also, the tool 20 may be permanently fixed to the tool mount 18. The tool 20 may include an energy application device designed to contact the tissue of the patient 12. In some examples, the tool 20 may be a saw blade 110 as shown in FIGS. 2A-2D, or other types of cutting aids. In such examples, the tool support may also be referred to as a blade support or a tool mount. Of course, in any example referred to as a blade support, this may be replaced with the term "tool support", and vice versa. The tool 20 may include a blade assembly and a drive motor that causes the oscillatory motion of the blade, as shown in U.S. Patent No. 9,820,753 to Walen et al. or U.S. Patent No. 10,687,823, which are incorporated herein by reference. Here, alternative rotary drive motors are contemplated. Such a drive component may be coupled to the drive motor DM and may include a transmission TM that converts the rotational motion from the drive motor DM into the oscillatory motion of the tool 20.

[0058] Surgical system 10 further comprises a navigation system 32. An example of the navigation system 32 is described in U.S. Patent No. 9,008,757, "Navigation System Including Optical and Non-Optical Sensors", filed on September 24, 2013, which is hereby incorporated by reference. The navigation system 32 tracks the movement of various objects. Such objects include, for example, the instrument 14, the tool 20, and biological structures (e.g., the femur F and the tibia T). The navigation system 32 tracks these objects to collect state information of each object with respect to the (navigation) localizer coordinate system LCLZ. For the purposes of use herein, the state of an object includes, but is not limited to, the position and / or orientation (e.g., its coordinate system) of the object being tracked, or data defining an equivalent / derivative of the position and / or orientation. For example, the state may be the pose of the object and / or may include linear velocity data, angular velocity data, etc.

[0059] The navigation system 32 may include a cart assembly 34 that houses a navigation controller 36 and / or other types of control units. The navigation user interface UI communicates operably with the navigation controller 36. The navigation user interface UI includes one or more displays 38. The navigation system 32 can use the one or more displays 38 to display a graphical representation of the relative state of the tracked object to the user. The navigation user interface UI further includes one or more input devices for inputting information to the navigation controller 36 or selecting / controlling a particular aspect of the navigation controller 36. Such input devices include an interactive touch screen display. However, the input device may include any one or more of push buttons, pointers, foot switches, keyboards, mice, microphones (voice-activated), gesture control devices, etc. In some examples, the user may explore and select icons and menus of the user interface UI and advance the settings and / or workflow of the surgical system 10 by using buttons disposed on the pointer.

[0060] In addition, the navigation system 32 includes a localizer 44 coupled to the navigation controller 36. In one example, the localizer 44 is an optical localizer and includes a camera unit 46. The camera unit 46 has an external casing 48 that houses one or more optical sensors 50. The localizer 44 may include its own localizer controller 49 and may further include a video camera VC.

[0061] The navigation system 32 includes one or more trackers. In some examples, the trackers include a pointer tracker PT, a tool tracker 52, a first patient tracker 54, and a second patient tracker 56. In the example shown in FIG. 1, the tool tracker 52 is firmly attached to the instrument 14, the first patient tracker 54 is firmly fixed to the femur F of the patient 12, and the second patient tracker 56 is firmly fixed to the tibia T of the patient 12. In this example, the patient trackers 54, 56 are firmly fixed to a part of the bone. The trackers 52, 54, 56, and the pointer tracker are aligned with their respective objects (e.g., bone, tool) and the navigation system 32 manually, automatically, or in combination thereof. In some examples, the pointer tracker PT is firmly attached to the pointer 57 and is used for aligning the biological structure with respect to one or more coordinate systems including the localizer coordinate system LCLZ and / or for other calibration and / or alignment functions. In one example, the pointer 57 may be used for aligning the trackers 54, 56 with respect to the bone to which the patient trackers 54, 56 are respectively attached, and may also be used for aligning the tool tracker 52 (and optionally 53) with respect to the tool mount 18, the tool 20, the tool platform 16, or a combination thereof. In some examples, the pointer tracker PT may be adapted to be used for aligning the TCP of the instrument 14 with respect to the tracker 52 with respect to the tracker coordinate system. Thus, when the localizer 44 moves from one position to another position, the alignment of the instrument 14 is defined with respect to the tool tracker 52. However, other alignment means for the trackers 52, 54, 56 are also conceivable and may be implemented together with the pointer tracker PT or may be implemented separately. Also, other tracker arrangements are conceivable.

[0062] The tool tracker 52 may be fixed to any suitable component of the instrument 14 and, in some versions, may be attached to the tool platform 16, to the tool mount 18, directly to the tool 20, or combinations thereof. The trackers 52, 54, 56, PT may be fixed to their respective components in any suitable manner, such as by fasteners or clamps. For example, the trackers 52, 54, 56, PT may be firmly fixed, flexibly connected (optical fiber), or not physically connected (ultrasonic), as long as there is a suitable (complementary) method for determining the relationship (measurement result) between each tracker and the object associated therewith. Any one or more of the trackers 52, 54, 56, PT may include an active marker 58. The active marker 58 may include a light emitting diode (LED). Alternatively, the trackers 52, 54, 56, PT may have a passive marker, such as a reflector, that reflects light emitted from the camera unit 46. Also, although not specifically described herein, suitable markers, such as printed markers, may be utilized.

[0063] For the purpose of tracking an object, various coordinate systems may be adopted. For example, the coordinate systems may include a localizer coordinate system LCLZ, a tool mount coordinate system TCS, a basic coordinate system BCS, coordinate systems respectively associated with trackers 52, 54, 56, PT, one or more coordinate systems associated with a biological structure, one or more coordinate systems (such as an implant coordinate system) associated with preoperative and / or intraoperative images (such as CT images, MRI images, etc.) and / or models (such as 2D or 3D models) of the biological structure, and a TCP (tool center point) coordinate system. In some examples, the surgical system 10 does not rely on preoperative and / or intraoperative imaging to generate a 2D or 3D model of the target bone. Instead, the surgical system may be used in an imageless system that uses a pointer tracker PT to align the target biological structure, and after capturing various anatomical landmarks, deforms a nominal bone model to match the captured data by processing by the control system 60. In other examples, after imaging the target area of the patient by preoperative and intraoperative imaging, the 2D and / or 3D images are converted into a 3D model of the target bone. It is also conceivable that the surgical system 10 may use a combination of image-based and image-free procedures to generate a 3D model of the target surgical area. An exemplary system is described in U.S. Patent No. 8,617,174, which is incorporated herein by reference. For example, when relationships between coordinate systems are established by alignment, calibration, geometric relationships, measurements, etc., coordinates in various coordinate systems may be converted to other coordinate systems using transformations.

[0064] In some examples, the TCP is a predetermined reference point or origin of a TCP coordinate system defined at the distal end of the tool 20. The shape of the tool 20 may be defined with respect to the TCP coordinate system and / or the tool support coordinate system TCS. The tool 20 is defined with respect to the TCP coordinate system and / or the tool support coordinate system TCS and may include one or more geometric features (e.g., outer perimeter, circumference, radius, diameter, width, length, height, volume, area, surface / plane, range of a motion envelope (along any one or more axes), etc.) stored in a non-volatile memory of the control board 31 in the control housing 29 of the instrument 14, the navigation system 32, the instrument controller 28, or a combination thereof. In one example, the tool center point (TCP) is a predetermined reference point and corresponding coordinate system defined in the tool 20. The TCP has a posture that is known or computable (i.e., not necessarily fixed) with respect to other coordinate systems. The TCP coordinate system includes an origin and a set of axes (e.g., x-axis, y-axis, z-axis) that define the posture of the TCP. By tracking the TCP (or by ascertaining the posture of the TCP), the system 10 can calculate the position and orientation of the instrument 14 based on the posture of the TCP and the known positional relationship between the TCP and the features of the instrument 14. In some examples, the tool 20 has a blade surface (e.g., of a saw blade) as described below for convenience and ease, but this is not intended to limit the tool 20 to any particular form. In other examples, the tool 20 has an axis. Also, the tool 20 can be virtually represented by the use of points, other primitives, meshes, other 3D models, etc. The origin of the TCP coordinate system may be located at the spherical center of the bur 25 of the tool 20, the tip of the drill bit, or the distal end of the saw blade 27 such that the TCP coordinate system is tracked with respect to the origin on the distal end of the tool 200. Alternatively, the TCP may be configured to be tracked by the use of multiple tracking points. The TCP can be defined in various ways depending on the configuration of the tool 20.The apparatus may employ joint / motor encoders, or any other non-encoder position sensing method, and for this reason, the control system 60 can determine the TCP pose and / or position with respect to the handheld portion 16 and the BCS. The tool support 18 may use the joint measurement results to determine the TCP pose and / or may employ a technique for directly measuring the TCP pose. The control of the tool 20 is not limited to the center point. For example, the tool 20 can be represented by the use of any suitable primitive, mesh, etc. Of course, the TCP may alternatively be defined as a point rather than a coordinate system. Once the pose of a tool such as a saw blade is determined by the TCP coordinate system, the calculation of any required reference point or geometry aspects of the tool becomes possible.

[0065] The localizer 44 monitors the trackers 52, 54, 56, PT (e.g., their coordinate systems) to determine the state of each of the trackers 52, 54, 56, PT, which respectively correspond to the state of the object to which each is attached. The localizer 44 may perform known techniques for determining the state of the trackers 52, 54, 56, PT as well as the associated objects (tool, patient, tool support, and handheld portion). The localizer 44 provides the state of the trackers 52, 54, 56, PT to the navigation controller 36. In some examples, the navigation controller 36 determines the state of the trackers 52, 54, 56, PT and communicates it to the instrument controller 28 or the console.

[0066] The navigation controller 36 may comprise one or more computers, or may comprise any other suitable form of controller. The navigation controller 36 has a central processing unit (CPU) and / or other processors, a memory, and a storage (not shown). As the processor, any type of processor, microprocessor, or multiprocessor system is possible. Software is loaded into the navigation controller 36. This software converts, for example, a signal received from the localizer 44 into data representing the position and / or orientation of the object to be tracked. In addition to or instead of this, the navigation controller 36 may comprise one or more microcontrollers, field programmable gate arrays, system-on-chips, discrete circuits, and / or other suitable hardware, software, or firmware capable of performing the functions described herein. The term processor is not intended to limit any embodiment to a single processor.

[0067] Although an example of the navigation system 32 for determining the state of an object is shown, the navigation system 32 may have any other suitable configuration for tracking the instrument 14, the tool 20, and / or the patient 12. In another example, the navigation system 32 and / or the localizer 44 is ultrasound-based. For example, the navigation system 32 may comprise an ultrasound imaging device coupled to the navigation controller 36. The ultrasound imaging device images any of the above-described objects (e.g., the instrument 14, the tool 20, and / or the patient 12) and generates a status signal to the navigation controller 36 based on the ultrasound image. The ultrasound image may be 2D, 3D, or a combination of both. The navigation controller 36 may process the image in substantially real time to determine the state of the object. The ultrasound imaging device may have any suitable configuration and may also be different from the camera unit 46 as shown in FIG. 1.

[0068] In another example, the navigation system 32 and / or the localizer 44 are radio frequency (RF)-based. For example, the navigation system 32 may include an RF transceiver coupled to the navigation controller 36. An RF radiator or transponder may be attached to the instrument 14, the tool 20, and / or the patient 12. The RF radiator or transponder may be passively powered or actively powered. The RF transceiver transmits an RF tracking signal and generates a status signal to the navigation controller 36 based on the RF signal received from the RF radiator. The navigation controller 36 may analyze the received RF signal and associate relative statuses therewith. The RF signal may be at any suitable frequency. The RF transceiver may be located at any suitable location to effectively use the RF signal to track an object. Further, the RF radiator or transponder may have any suitable structural configuration that may be significantly different from the trackers 52, 54, 56, PT shown in FIG. 1.

[0069] In yet another example, the navigation system 32 and / or the localizer 44 are electromagnetic-based. For example, the navigation system 32 may include an EM transceiver coupled to the navigation controller 36. EM elements such as any suitable magnetic tracker, electromagnetic tracker, inductive tracker, etc. may be attached to the instrument 14, the tool 20, and / or the patient 12. The tracker may be passively powered or actively powered. The EM transceiver generates an EM field and generates a status signal to the navigation controller 36 based on the EM signal received from the tracker. The navigation controller 36 may analyze the received EM signal and associate relative statuses therewith. Similarly, in such an example of the navigation system 32, it may have a structural configuration different from the configuration of the navigation system 32 shown in FIG. 1.

[0070] The navigation system 32 may have any other suitable components or structures not specifically enumerated herein. Further, any of the techniques, methods, and / or components described above with respect to the illustrated navigation system 32 may be implemented or provided for any of the other examples of the navigation system 32 described herein. For example, the navigation system 32 may utilize inertial tracking only or any combination of tracking techniques, and in addition to, or instead of, this, may include fiber-optic based tracking, machine vision tracking, and the like.

[0071] Referring to FIGS. 2A-2F, a first configuration of the blade cartridge 110 for use with the surgical instrument 14 of the surgical system of FIG. 1 is shown. The sagittal blade cartridge 110 may be referred to as a sagittal blade cartridge, a surgical blade cartridge, or simply a cartridge. The blade cartridge 110 may include a guide bar 111. The guide bar 111 may include a plurality of plates 112, 114, 116 (including a first plate 112, a second plate 114, and a third plate 116). The guide bar 111 may be configured such that the third plate 116 can be disposed between the first plate 112 and the second plate 114. For this reason, the first plate 112 may be referred to as the lower plate, the second plate 114 may be referred to as the upper plate, and the third plate 116 may be referred to as the inner plate, the central plate, the inner member, the central layer, and / or the central member. Although the guide bar 111 is shown as including only three plates laminated in a laminated arrangement, it is also contemplated that the guide bar 111 may include any number of plates and / or layers.

[0072] Overall, these plates are formed such that the guide bar 111 has a proximal portion 118 that constitutes the proximal ends 118A, 118B, 118C of the plates 112, 114, 116. The proximal portion 118 of the guide bar 111 may be configured to first taper outwardly along the guide bar 111 in the distal direction and then finally taper inwardly along the guide bar 111 further in the distal direction. The outward taper of the proximal portion 118 of the guide bar 111 may be configured as an attachment feature to assist in the attachment and / or fixation of the saw blade cartridge 110 to a surgical instrument 14 such as a surgical robot or a handheld instrument. For example, as shown in FIGS. 2B and 2C, the opposing outer edges of the proximal portion 118 of the guide bar 111 may define a contact surface with the tool mount 18. Further, one or both of the proximal portions 118A, 118C of the first and / or second plates 112, 114 may be shaped to define a recess 136 that exposes a portion 134 of the proximal portion 118B of the third plate 116 at the outer edges of the proximal portions 118A, 118C of the first and / or second plates 112, 114, or may be considered to include a recess or notch 136. As shown in FIG. 2B, the recess 136 may be sized and / or shaped to expose only a small portion 134 of the third plate, such as a tab 134 of the third plate 116 exposed by the recess 136 defined in the proximal portion 118 of the first plate 112. Alternatively, the recess 136 defined by the proximal portion of the first plate 112 may include the entire proximal portion 118 of the first plate 112 that is removed to expose the distal ledge of the third plate along the proximal edge of the proximal portion of the guide bar 111. In any configuration, the portion 134 of the proximal end 18B of the third plate 116 exposed by the recess 136 defined at the outer edge of the first or second plate 112, 114 may be configured as one of the portions 134 of the guide bar 111 that contacts and / or interacts with the mount 18 of the surgical instrument 14 for the attachment and / or alignment of the surgical blade cartridge 110 to the surgical instrument 14.This will be described in more detail below.

[0073] Referring to FIG. 2B, the opposing outer edges of the proximal portion 118 of the guide bar 111 may include a number of points 139, 141, 143 that are spaced along the outer peripheral edge of the proximal portion 118. Points 139, 141, 143 along the edge of the proximal portion 118 of the guide bar 111 may define a plurality of segments 140, 142 of the outer edge of the proximal portion 118 of the guide bar 111, each of which may have a different taper with respect to the longitudinal axis L extending from the proximal end 118 to the distal end 120 of the guide bar 111. For example, the outer edge of the proximal portion 118 of the guide bar 111 may include a first segment 140 defined between a first point 139 and a second point 141. The first segment 140 may have a first outward taper such that the second point 141 is farther from the longitudinal axis L of the guide bar 111 than the first point 139. The outer edge of the proximal portion 118 of the guide bar 111 may include a second segment 142 defined between the second point 141 and a third point 143. The second segment 142 may have a second outward taper such that the third point 143 is farther from the longitudinal axis L of the guide bar 111 than the second point 141. The proximal portion 118 of the guide bar 111 may be configured such that the first and second segments 140, 142 each have a different taper with respect to the longitudinal axis L of the guide bar 111. The taper and / or orientation of each of the segments 140, 142 of the opposing outer edges of the proximal portion 118 of the guide bar 111 may correspond and / or match the angle and / or taper of the surface of the bracket 68 of the mount 18 for securing the saw blade cartridge 110 to the surgical instrument 14, as will be described in more detail below.

[0074] The proximal portion 118 of the guide bar 111 may further include a proximal edge 144 that is oriented generally perpendicular to the longitudinal axis of the guide bar 111. A recess 128 may be defined in the proximal edge 144 of the guide bar 111. The recess 128 may be formed in the proximal edge 144 of the guide bar 111 on one side or the other side of the longitudinal axis L of the guide bar 111. The recess 128 may function as an aid for alignment and / or placement during the manufacture of the guide bar 111 (including the manufacture of the individual plates 112, 114, 116 that make up the guide bar). Further, it is conceivable that the recesses 128 formed in each of the first, second, and / or third plates 112, 114, 116 may differ in size and / or shape. For example, as shown in FIGS. 2B and 2E, the recesses 128 formed in the first and third plates 112, 116 are deeply cut into the proximal portions of the respective plates and have a larger radius than the recess 128 formed in the second plate 114. This may enable the first and second plates 112, 114 to be distinguished during the manufacture of the guide bar 111, where otherwise the first and second plates 112, 114 may look very similar to each other. Also, the difference in size and / or shape of the recesses 128 formed in the first and second plates 112, 114 may assist the user in properly attaching the guide bar to the mount of the surgical instrument 14.

[0075] In front of the proximal portion 118 of the guide bar 111 are the central portion and the distal portion 120. The plates 112, 114, 116 are formed such that the opposing side portions of the guide bar that constitute the side portions of the central portion are generally parallel. In some configurations, the opposing side portions of the distal portion 120 of the guide bar 111 may be tapered. As shown in the drawings, the opposing edges 132, 199 of the distal portion 120 of the guide bar 111 may be tapered inwardly toward the center of the plates 112, 114, 116. Also, it is conceivable that the opposing edges of the distal portion 120 of the guide bar 111 may be generally parallel to each other. The width across the central portion and / or the distal portion 120 of the guide bar 111 may be smaller than the width of the proximal portion 118 at the widest point between the opposing edges of the proximal portion 118 of the guide bar 111.

[0076] The proximal portions 118 of each of the plates 112, 114, 116 may further include two laterally spaced openings 122, 188 (one is identified). As shown in the drawings, the first plate may include a pair of openings 122, and the second plate 114 may include a pair of openings 188. The third plate 116 may or may not define an opening depending on its shape. As shown in the drawings, the third plate 116 is shaped to define channels 150A, 150B that cooperate with the openings 122, 88 defined in the first and second plates 112, 114. The illustrated plates include a pair of openings 122, 188 defined in the first and second plates 112, 114 and a pair of channels 150A, 150B defined by the third plate 116. However, the guide bar 111 may be formed such that a single opening is formed in each of the plates 122, 188, or may be formed such that three or more openings 122, 188 are defined in each of the plates 112, 114, 116. The openings 122, 188 may be formed in a semi-elliptical shape. Each opening 122, 188 has a portion curved toward the proximal end of the plates 112, 114, 116 and a straight portion toward the distal end of the guide bar 111.

[0077] In front of the openings 122, 188, at least one of the plates 112, 114, 116 may be configured to define keyhole-shaped openings 126, 152, 190. As shown in the drawings, the second plate 114 may define a keyhole-shaped opening 126, and the first and third plates 112, 116 define openings 152, 190 that cooperate with the keyhole-shaped opening 126 of the second plate 114. In the drawings, the keyhole-shaped opening 126 is shown only in the second plate 114, but it is also conceivable that one, two, or all three of the plates 112, 114, 116 may define keyhole-shaped openings 126, 152, 190. For example, it is also conceivable that the third plate 116 defines a keyhole-shaped opening 152, and the first and second plates 112, 114 define general openings 126, 190 such as openings in the shape of a square, a circle, an ellipse, etc. Referring to FIG. 2B, the keyhole-shaped opening 126 is shaped such that its widest part can receive the fastening mechanism of the mount for the saw blade cartridge 110. The openings 126, 152, 190 defined in each of the plates 112, 114, 116 may be located at the center between the opposing edges of the guide bar 111 so as to extend between the proximal end 118 and the distal end 120 of the guide bar 111 and bisect the guide bar 111 on the longitudinal axis L. Further, the keyhole-shaped opening 126 may be formed such that its narrower part is disposed forward in the distal direction of the wider part, so that the fastening mechanism 62 of the tool mount 18 can slide within the opening 126.

[0078] Furthermore, at least one of the plates 112, 114, 116 of the guide bar 111 may include an opening 130 or an aperture configured to provide access to a reference feature 156 disposed on one of the other plates 112, 114, 116 of the guide bar 111 and / or to expose the reference feature 156. For example, as shown in FIGS. 2C and 2F, the guide bar 111 may include first, second, and third plates 112, 114, 116. The first or second plate 112, 114 may include an opening 130 that provides access for a pointer 57 to a reference feature 156 disposed on the third plate 116.

[0079] Referring to FIG. 2C, one configuration of the guide bar 111 may include a plurality of additional openings 130 formed in the first and / or second plates 112, 114 and configured to perform identification and / or alignment of the saw blade cartridge 110 within a known coordinate system of the surgical navigation system 32. For example, at least one of the first and / or second plates 112, 114 may define at least three openings 130A, 130B, 130C. The openings 130A, 130B, 130C defined in the first and / or second plates 112, 114 may be defined on the third plate 116 and may be configured to provide access to reference features 156A, 156B, 156C corresponding to each of the openings 130A, 130B, 130C. The reference feature 156 may include a portion of the surface of the third plate 116 exposed by the openings 130A, 130B, 130C. The openings 130A, 130B, 130C may further function to define contact points on the third plate 116 for identification and / or alignment of the orientation of the saw blade cartridge 110 by the navigation system 32. The openings 130A, 130B, 130C may be considered to include openings in the shape of a circle, square, rectangle, or other similar polygon that provide access to the reference feature 156 on the surface of the third plate 116. Although not shown in the drawings, the reference feature 156 may be defined on the third plate 116 and may further include a recess, indent, divot, mark, or similar marking accessible through the openings 130A, 130B, 130C defined in one of the first or second plates 112, 114. This may include a depression on the surface of the third plate accessible through one of the openings 130A, 130B, 130C in one of the first plate 112 or the second plate 114. Further, the reference feature 156 may be considered to include markings such as laser markers (without any physical recesses, depressions, or openings). The markings may be realized as etches, colors, engravings, or similar optical markings.

[0080] Typically, the guide bar 111 may include three or more openings 130A, 130B, 130C corresponding to three or more reference features 156A, 156B, 156C such that the navigation system 32 can define the plane of the surgical saw blade cartridge 110. However, additional openings 130A, 130B, 130C and corresponding reference features 156A, 156B, 156C may be defined on the guide bar 111. Further, the openings 130A, 130B, 130C and corresponding reference features 156A, 156B, 156C are spaced apart from each other such that a straight line cannot be drawn that intersects all of the reference features 156A, 156B, 156C.

[0081] The reference features 156A, 156B, 156C and thus the openings 130A, 130B, 130C may be disposed on the guide bar 111 at known positions relative to the particular positions of the reference features 156A, 156B, 156C on the guide bar 111, as well as at the positions of each of the other reference features 156A, 156B, 156C relative to each of the reference features 156A, 156B, 156C. The known positions of the reference features 156A, 156B, 156C on the guide bar 111 are utilized to define the position of the guide bar 111 and / or the surgical saw blade cartridge 110 within a known coordinate system of the navigation system 32. The known positions of the reference features 156A, 156B, 156C are utilized by the navigation system 32 to calculate the expected positions of each of the reference features 156A, 156B, 156C based on the geometric characteristics and mechanical stack-up of the surgical instrument 14 and the surgical saw blade cartridge 110, respectively, as will be described in more detail below, as part of the alignment process.

[0082] As best seen in FIG. 2F, the third plate 116 is formed to have a proximal portion 118B. A pair of laterally spaced tines 146 may extend forwardly from the proximal portion 118B of the third plate 116. The tines 146 may be referred to as outer tines. The outer surface of the tines 146 is the outer surface of the third plate 116 that constitutes a partial region of the outer surface of the guide bar 111. Thus, the outer tines 146 extend forwardly from the proximal portion 118B and have a proximal region that tapers outwardly in the distal direction along the third plate 116 and then tapers inwardly. The outer tines 146 are symmetrically disposed with respect to the longitudinal axis L of the guide bar 111. Further, the outer tines 146 are shaped such that they are mirror images of each other and are mirrored with respect to the longitudinal axis L. Further, the outer tines 146 may be configured to integrally couple the first, second, and third plates 112, 114, 116 to form the guide bar 111. For example, the first and second plates 112, 114 may constitute the guide bar 111 by welding or similar coupling to the outer tines 146 of the third plate 116. Or, it is also conceivable that the first and second plates 112, 114 may constitute the guide bar 111 by welding or similar coupling to the inner tines 148 of the third plate 116. Welding or similar coupling of the first and second plates 112, 114 to the inner tines 148 of the third plate 116 can avoid any interference, unintended warping, or similar inhibition to the edge of the proximal portion 118 of the third plate 116, which can be utilized for the alignment and / or orientation of the guide bar 111 with respect to the surgical instrument 14.

[0083] Also, the portion adjacent to the distal end of each tine 146 is shaped to have a lobe 160 that extends inwardly toward the longitudinal axis L of the guide bar 11. As it goes from the proximal direction to the distal direction along the tine 146, the associated lobe 160 curves inwardly toward the longitudinal axis L of the guide bar 11 and then curves outwardly.

[0084] The third plate 116 may further include a third tine 148 disposed between the outer tines 146 and being an inner tine centered about the longitudinal axis L of the guide bar 111. As described above, the inner tine 148 may be formed to define an opening 152, which may be a keyhole-shaped opening 152. The inner tine 148 may be shaped such that the opening 152 has the same shape as the openings 126 and 190 of the first and second plates 112, 114 respectively and is arranged in alignment with the openings 126 and 190. The inner tine 148 has a constant width except at its distal end. At the most distal end, the inner tine 148 may include a head 158, which faces in the distal direction and has a surface configured to curve and define a pivoting surface. Although not shown in the drawings, it is also contemplated that the head 158 may define a concave surface configured to receive a rocker or a curved surface, and the rocker or curved surface is pivotable within the concave surface defined by the head 158. The head 158 may include a center defining the radius of the surface facing in the distal direction that curves to define the pivoting surface.

[0085] The drawings show the inner tine 148 disposed between the outer tines 146, but it is also contemplated that the third plate 116 may not have the inner tine 148 formed thereon and may only comprise two outer tines 146 spaced apart from each other. In such a configuration, the pivot pin may be coupled adjacent to the blade head. In other words, although the illustrated third plate has three tines formed as a single piece, it is also contemplated that the three tines may be formed separately and fixed between the first and second plates.

[0086] Since the outer tine 146 is spaced apart from the inner tine 148, the third plate 116 defines a pair of elongated closed-end slots 150A, 150B between each outer tine 146 and the inner tine 148. The proximal ends of the slots 150A, 150B are the closed ends of the slots. When assembling the cartridge 110, each slot 150A, 150B is disposed on a respective separate opening 122, 188 of the first and second plates 112, 114. The third plate 116 is further formed such that the proximal ends of each slot 150A, 150B have a shape that is substantially equal to the shape of the openings 122, 188 of the first and second plates 112, 114. For this reason, the lateral width of the proximal ends of each slot 150A, 150B is greater than the width of the slots 150A, 150B in front of the distal direction of the proximal portion 118.

[0087] Although the third plate 116 is generally shown in the drawings as a single unitary or single plate, it is also conceivable that it could be configured as a plurality of separate components arranged to constitute the above-described features and / or parts of the third plate 116. For example, the proximal portion 118 of the third plate 116 could be formed as a unitary component including the outer tine 146, and the inner tine 148 could be a separate component. Alternatively, the inner tine 148 could be omitted. In yet another exemplary configuration, the proximal portion 118, the outer tine 146, and the inner tine 148 of the third plate 116 could all be formed as separate components.

[0088] Referring to FIGS. 2A - 2F, it can be seen that the first plate 112 is shaped to have substantially the same outer perimeter as the outer perimeter of the second plate 114. However, it is also conceivable that one of the first plate 112 or the second plate 114 may be longer / shorter and / or narrower / wider than the other plate. For example, the second plate 114 may be configured such that its outer perimeter is narrower, i.e., the outer edge is closer to the longitudinal axis L than the outer edge of the first plate 112. In front of the proximal portions 118 of the first and second plates 112, 114, a distal portion 120 is located. The distal portions of the first and second plates 112, 114 are shaped to have two openings 124, 196. The openings 124, 196 are identical in shape and are arranged such that the opening 124 in the first plate 112 is aligned with the opening 196 in the second plate 114.

[0089] The saw blade cartridge 110 may further include a saw blade 170 disposed between the first and second plates 112, 114 at the distal end of the saw guide bar 111. The saw blade 170 is formed to have a blade body 172 and a blade head 174. The saw blade 170 is formed such that the thickness of the blade body is equal to or less than the thickness of the third plate 116. As seen in FIG. 2F, the blade body 172 of the saw blade 170 is generally rectangular in shape. However, it is also conceivable that the outer peripheral edge of the blade body 172 may be tapered and / or curved. The taper and / or curve may match the taper or curve of the lobe 160 of the outer tine 146 of the inner plate 116. The shape of the blade body may be configured such that the blade body 172 can pivot around the head 158 of the inner tine 148 and oscillate between the lobes 160 of the outer tine 146.

[0090] When the saw blade 170 is in the central position within the guide bar 111, the spindle of the blade body 172 is collinear with the longitudinal axis L of the guide bar 111. The blade body 172 may be shaped to have two feet 184 (one foot is identified). The feet 184 have the same thickness as the blade body 172. Each foot 184 extends to the open ends of the slots 150A, 150B inside the inner teeth 148. Between the feet 184, the blade body 172 is formed to have a curved surface 180 facing in the proximal direction. The blade body 172 is shaped such that the surface 180 is mounted against the head 158 integral with the inner teeth 148 and can pivot around the head 158. The drawings show a third plate including the inner teeth 148 that define the head 158 around which the saw blade pivots, but it is also conceivable that the guide bar is configured to have pins disposed between the first and second plates 112, 114 and the saw blade 170 is configured to pivot around the pins. The blade feet 184 and the blade body 172 may also be referred to as the base of the saw blade 170.

[0091] The distal end of the blade body 172 extends distally of the guide bar 111 such that the blade head 174 extends in front of the distal end of the guide bar 111. A plurality of teeth 176, 178 are formed on the blade head 174. Referring to FIG. 2D, the saw blade 170 is further formed such that the thickness of the blade head 174 is greater than the thickness of the blade body 172. More specifically, the blade head 174 is formed to have a thickness greater than or equal to the thickness of the guide bar 111 such that the cut formed by the cutting operation of the saw blade 170 is sufficient for the reception of the guide bar 111.

[0092] Referring to FIGS. 2A-2C, the blade head 174 may comprise two types of teeth, namely base teeth 178 and one or more pilot teeth 176. For example, as shown in FIG. 2C, the blade head 174 may comprise two pilot teeth 176. However, it is also contemplated that the blade head 174 may comprise a single pilot tooth or three or more pilot teeth. The pilot teeth 176 may be disposed proximate to the center of the distal face of the blade head 174. Further, the pilot teeth 176 may be configured to extend distally beyond adjacent base teeth 178 of the blade head 174. In operation, the pilot teeth 176 are configured to oscillate about a first arc that is more distal than a second arc when the adjacent base teeth 178 oscillate about the second arc while extending distally beyond the adjacent base teeth 178. An exemplary surgical blade cartridge having pilot teeth is disclosed in International Patent Application No. PCT / US2021 / 064328, filed Dec. 20, 2021, the entire contents of which are incorporated herein by reference.

[0093] Optionally, the blade head 174 may include a notch or opening 175. As shown in the drawings, a single notch 175 is formed in the blade head. However, it is also conceivable that any number of notches or openings 175 may be formed in the blade head 174. The notch 175 may be formed in a teardrop shape or generally circular shape. The notch 175 may be configured to allow removal of foreign matter during cutting. Also, the opening 175 may be configured to allow cooling of the blade 70 and / or the blade head 74 during cutting. Further, the notch 175 may be configured to assist in the manufacture of the blade 170. For example, when manufacturing the blade 170, the notch 175 may be machined and / or formed in the blank piece of material from which the blade is formed. Thereafter, the notch 175 may be used as a reference point during manufacture, such that the blade body 172, the blade head 174, and / or the teeth 176, 178 may be machined / formed. For example, the manufacturing process may be set such that the opening 175 is identifiable and the machining tool is programmed to cut and / or grind the blank piece of material at a location based on the opening 175 to form the teeth.

[0094] Inside the guide bar 111, drive links 162 are disposed in slots 150A and 150B respectively. Each drive link 162 is in the form of an elongated flat metal strip. The drive link 162 is formed such that a foot portion 164 exists at the proximal end of each link. Each foot portion 164 is formed to have a through hole 166 (one opening is identified) disposed at the center. The through hole 166 is formed to have a size such that the associated drive link foot portion 164 can be fitted to a saw head drive pin. Each drive link 162 is shaped such that the thickness of the foot portion 164 is greater than the thickness of the metal strip constituting the body of the link 162. The thickness of the foot portion 164 is typically not greater than the thickness of the guide bar 111. When assembling the cartridge 110, the foot portion 164 is typically installed at the proximal end portions of the associated slots 150A and 150B. The portion of each foot portion 164 that protrudes outward from the body of the link 162 is installed in the openings 122 and 188 of the first and / or second plates 112 and 114.

[0095] The drive link 162 may further include two finger portions 168 (one finger portion is identified) that extend distally forward from the distal end of the body of each drive link 162. The finger portions 168 overlap and are spaced apart from each other. More specifically, the finger portions 168 are spaced apart from each other by a sufficient distance such that a blade foot portion 184 can be installed between each pair of finger portions. A hole 182 is formed in each finger portion 168. The holes 182 of each pair of finger portions 168 are aligned with each other.

[0096] Referring to FIGS. 2B and 2F, the distal portion of the guide bar 111 may include a pair of generally elliptical openings 198 in the first plate 112. Although the drawings show two openings 198, it is also contemplated that the guide bar 111 may be configured to have a single opening or three or more openings. Further, although the openings shown in the drawings are defined in the first plate 112, it is also contemplated that similar openings may be defined in the second plate 114. The openings 198 may include curved and / or bent portions that extend longitudinally along the length of the distal portion 120 of the first plate 112. The openings may be configured to assist in removing foreign matter that may be captured between the first and second plates 112, 114 when the saw blade cartridge 110 is utilized for cutting biological tissue.

[0097] Also, the distal portion 120 of the guide bar 111 may be formed to define a notch or slot 138 between the first and second plates 112, 114. As shown in FIG. 2A, the outer tine 146 of the inner plate 116 is formed such that the most distal point of the lobe 160 of the outer tine 146 is disposed proximal to the most distal edges of the first and second plates 112, 114. This configuration defines a slot 138 along the side edges of the guide bar 111 that can assist in removing foreign matter that may be captured between the first and second plates 112, 114 when the saw blade cartridge 110 is utilized for cutting biological tissue. Also, the slot 138 along the side edges of the guide bar 111 can serve to increase the range of motion during pivoting of the saw blade 170. By shortening the length of the outer tine 146, the gap is increased, so that the saw blade can pivot further, increasing the distance by which the blade head 174 can vibrate.

[0098] Referring to FIGS. 3A - 3G, a second configuration of the saw blade cartridge 210 is shown. It should be understood that the components and / or features of the second configuration of the saw blade cartridge 210, having the same reference numerals increased by 100 (i.e., 110 and 210), may operate in a similar or identical manner to those described above.

[0099] Similarly to the above, the second configuration of the saw blade cartridge 210 may include a guide bar 211 having a plurality of plates (212, 214, 216) including a first plate 212, a second plate 214, and a third plate 216. The guide bar 211 may be configured such that the third plate 216 can be disposed between the first plate 212 and the second plate 214. The first, second, and third plates 212, 214, 216 are configured identically or similarly to the saw blade cartridge 110 described above. However, the second configuration of the saw blade cartridge 210 shown in FIGS. 3A-3G is configured to have reference features 256 of an alternative configuration disposed on the guide bar.

[0100] Referring to FIGS. 3A-3G, the above-described saw blade cartridge 210 shown is included with reference features 256A, 256B, 256C, 256D of an alternative configuration. As described above, the saw blade cartridge 210 may include a plurality of reference features 256A, 256B, 256C, 256D. FIGS. 3B, 3E, and 3F show a surgical saw blade cartridge 210 including exemplary arrangements of the reference features 256A, 256B, 256C, 256D. The reference features 256A, 256B, 256C, 256D shown in the drawings are disposed on the second plate 114, although it is also conceivable that these plurality of reference features 256A, 256B, 256C, 256D can be disposed on the first or second plates 212, 214. Further, the reference features 256A, 256B, 256C, 256D of a particular saw blade cartridge may be placed on any combination of the first, second, and / or third plates 212, 214, 216.

[0101] As described above, the reference feature portions 256A, 256B, 256C, and 256D may be formed as openings, depressions, imprints, color markings, or similar markings or indicia. For example, as shown in FIG. 3E, the reference feature portions 256A, 256B, 256C, and 256D may include one or more indicia or similar visual markings disposed on the second plate 214. The reference feature portions 256A, 256B, 256C, and 256D may be defined as indicia disposed on the surface of the second plate 214, such as the cross markings shown in FIG. 3E. The examples of the reference feature portions 256A, 256B, 256C, and 256D shown in FIG. 3E are represented by cross markings, but other shapes and / or forms of visual markings are also conceivable. For example, the reference feature portions 256A, 256B, 256C, and 256D may be defined by circular markings, triangular markings, X-shaped markings, etc. The markings representing the reference feature portions 256A, 256B, 256C, and 256D may be formed on the guide bar 211 by laser marking, scoring, drawing, imprinting, or a similar marking process.

[0102] Alternatively, the reference feature portions 256A, 256B, 256C, and 256D may be formed as depressions or recesses formed on the surface of the second plate 214. In yet another configuration, the reference feature portions 256A, 256B, 256C, and 256D may be defined by a combination of the above-described features. For example, the reference feature portions 256A, 256B, 256C, and 256D may include a depression formed on the surface of the second plate 214 and an indicium provided within the depression that applies to the depression and defines the reference feature portions 256A, 256B, 256C, and 256D as a visual identifier.

[0103] The reference features 256A, 256B, 256C, 256D may be disposed on the guide bar 211 at known positions relative to the specific positions of the reference features 256A, 256B, 256C, 256D on the guide bar 211, and also at the positions of the other reference features 256A, 256B, 256C, 256D relative to each of the reference features 256A, 256B, 256C, 256D. The known positions of the reference features 256A, 256B, 256C, 256D on the guide bar 211 are used to define the position and / or orientation of the guide bar 211 and / or the surgical saw blade cartridge 210 within the known coordinate system of the navigation system 32. The known positions of the reference features 256A, 256B, 256C, 256D are utilized by the navigation system 32 to calculate the expected positions of the respective reference features 256A, 256B, 256C, 256D based on the geometric characteristics and mechanical stack-up of each of the surgical instrument 14 and the surgical saw blade cartridge 210, as will be described in more detail below, as part of the alignment process.

[0104] Referring to FIG. 3E, a reference feature 356 of an alternative configuration is shown. The reference feature 356 may include a visual marker disposed on at least one surface of the plates 112, 114, 116 of the guide bar 111. For example, the reference feature 356 may include a visual mark disposed on the second plate 114 of the guide bar 111. The reference feature 356 may include a traceable line disposed on the guide bar 111. This line may indicate the position of a portion of the contour of the tool mount 18. Also, a pointer 57 may be utilized to trace a line representing the reference feature 356 to define a plane of the surgical saw blade cartridge 110 within a known coordinate system of the navigation system 32. In FIG. 3E, an exemplary configuration of the path traced by the pointer 57 is shown by a dotted line, but it is also contemplated that the reference feature 356 may not physically and / or visually exist on one of the plates 112, 114, 116 of the guide bar 111. For example, as will be described in more detail below, the process of aligning the surgical saw blade cartridge 110 within a known coordinate system of the navigation system 32 may include tracing a path / line (similar to the path shown by the dotted line) along the contour of the tool mount 18 on the guide bar 111 that does not have a visual or physical reference feature defined thereon. This method may further include tracing a portion of the tool mount that is different from the portion shown.

[0105] Referring to FIGS. 4A-5B, the above-described surgical saw blade cartridge 110 shown is including alternative configured blade heads 174A, 174B. Similar to the above-described blade head 174, the configurations of the blade heads 174A, 174B shown in FIGS. 4A and 4B may each include two types of teeth, namely base teeth 178 and one or more pilot teeth 176. Also optionally, the configurations of the blade heads 174A, 174B may each include a notch or opening 175. As shown in the drawings, the blade heads 174A, 174B are each formed with a single notch 175 generally in a teardrop shape. As described above, additional notches or openings 175 may be formed in the blade heads 174A, 174B, and the notches or openings 175 may be formed in alternative shapes.

[0106] The first configuration of the blade head 174A as shown in FIGS. 4A and 5A may have a first width D3. Alternatively, the second configuration of the blade head 174B as shown in FIGS. 4B and 5B may have a second width D4. The blade heads 174A, 174B may be configured such that the first width D3 of the first configuration of the blade head 174A is longer (wider) than the second width D4 of the second configuration of the blade head 174B. The blade heads 174A, 174B may each typically have a similar shape, but the first configuration of the blade head 174A and the second configuration of the blade head 174B may be adapted for different surgical procedures. For example, the narrower second configuration of the blade head 174B may be more suitable for smaller cuts and / or incisions in more limited spaces. Also, the narrower second configuration of the blade head 174B may be more suitable for more precise incisions. Alternatively, the wider first configuration of the blade head 174A may be more suitable for forming larger cuts and / or cutting denser materials or biological tissues.

[0107] Similarly, in all configurations of the saw blade cartridges 110, 210, they do not have to have all of the above features. For example, in all configurations of the saw blade cartridges 110, 210, it is not necessary to include outer teeth that extend in front of the inner teeth. In yet another example, not all outer teeth necessarily have to include lobes that face inward.

[0108] Similarly, in some versions of the saw blade cartridges 110, 210, one or both of the first plates 112, 212 or the second plates 114, 214 may be formed on all or part of the inner plates 116, 216. Thus, in these versions of the saw blade cartridges 110, 210, when a blank is formed, this blank is machined so that the drive rod is installed and a slot that defines the outer periphery of the teeth is defined. Alternatively, the openings and slot defining portions of the guide bar may be formed by molding.

[0109] In some versions of the saw blade cartridges 110, 210, only a single drive link may be required for pivoting the blade head. In some versions of the saw blade cartridges 110, 210, one or more drive links do not have to be parallel to the longitudinal axis passing through the cartridge. Thus, in these versions of the saw blade cartridges 110, 210, the openings in the guide bar where the elements of one or more drive links are installed do not have to be aligned on a line parallel to the longitudinal axis passing through the cartridge either.

[0110] In versions of the saw blade cartridges 110, 210 having at least one drive link and teeth complementary to the blade, the guide bar may have a structure different from those described heretofore. Specifically, the guide bar may be formed such that the blade head is not an integral part of one of the plates forming the guide bar. In these versions of the saw blade cartridges 110, 210, the structure about which the blade pivots may be a pin attached to or integrated with at least one of the plates forming the guide bar.

[0111] In some versions of the saw blade cartridges 110, 210, not all two or three of the plates forming the guide bar need be three different plates integrally welded or fixed. In these alternative versions of the saw blade cartridges 110, 210, a plurality of plates are integrally machined or molded as a single unit.

[0112] Referring to FIGS. 6A - 6D, one configuration of the surgical instrument 14 and pointer 57 of the surgical system 10 described above is shown. The surgical instrument 14 comprises a surgical saw blade cartridge 110 removably coupled to a tool platform 16 via a tool mount 18. Further, the surgical instrument 14 includes a tracker 52 coupled and associated with the tool platform 16 of the surgical instrument 14, and the tracker 52 is configured such that a navigation system 32 can determine the orientation of the tool platform 16 within a known coordinate system.

[0113] The tool platform 16 may further include one or more markers 60A, 60B, 60C, 60D. The markers 60A, 60B, 60C, 60D may also be referred to as standard or reference features. The markers 60A, 60B, 60C, 60D may be configured to align the posture of the tool platform 16 in a known coordinate system defined by the navigation system 32 by touching one or more of the markers 60A, 60B, 60C, 60D using the pointer 57 while tracking the pointer tracker PT and the tracker 52 of the surgical instrument.

[0114] Surgical saw blade cartridges 110, 210 are removably coupled to the tool platform 16 of the surgical instrument 14. The surgical saw blade cartridges 110, 210 include guide bars 111, 211 composed of a plurality of plates 112, 114, 116, 212, 214, 216. For example, as described above, the guide bars 111, 211 may include three plates 112, 114, 116, 212, 214, 216 that are stacked on each other to form the guide bars 111, 211.

[0115] The plates 112, 114, 116, 212, 214, 216 of the guide bars 111, 211 may further include and / or define one or more reference features 156, 256. The reference features 156, 256 may function as contact points of the pointer 57 for aligning the surgical saw blade cartridges 110, 210 in a known coordinate system of the navigation system 32. For example, the guide bars 111, 211 may include and / or define three reference features 156, 256 that are used to define the plane of the surgical saw blade cartridges 110, 210 in a known coordinate system of the navigation system 32 when contacted by the pointer 57.

[0116] Also, as described above, the surgical system may include a pointer 57 for aligning the posture of the tool platform 16 and / or the postures of the surgical saw blade cartridges 110, 210 within the known coordinate system of the navigation system 32. The pointer 57 may include a pointer tracker PT that can be identified and tracked by the localizer 44 of the navigation system 32.

[0117] During operation, the distal end 59 of the pointer 57 is brought into contact with the markers 60A, 60B, 60C, 60D of the tool platform 16 and / or the reference features 156, 256 of the surgical saw blade cartridges 110, 210 to identify the positions of the tool platform 16 and / or the surgical saw blade cartridges 110, 210 within the known coordinate system of the navigation system 32 relative to the tracker 52 of the surgical instrument 14. This can be achieved by the localizer tracking the posture of the pointer 57 as the pointer moves from each of the markers 60A, 60B, 60C, 60D of the tool platform 16 and / or the reference features 156, 256 of the surgical saw blade cartridges 110, 210 to the next marker 60A, 60B, 60C, 60D and / or reference feature 156, 256.

[0118] Referring to FIGS. 6A and 6B, the distal end 59 of the pointer 57 may be formed in the shape of a sphere or ball. As described above, the reference features 156, 256 of the surgical saw blade cartridges 110, 210 may be defined as recesses, depressions, indentations, markings, or similar markings on the guide bars 111, 211. The reference features 156, 256 may be defined by markings such as laser markings or similar visual markers on the guide bars 111, 211 rather than physical markings such as recesses or depressions.

[0119] The distal end 59 of the pointer 57 is sized and / or shaped to fit within the opening 130 defined in the first or second plate 112, 114 of the guide bar 111 described above so that contact with a reference feature disposed on the third plate 116 is not impeded and / or blocked. For example, as shown in FIG. 6B, the distal end includes a spherical tip of a first diameter D1. The opening may have a second dimension D2. The second dimension D2 may define the diameter of a circular or elliptical opening. Alternatively, the second dimension D2 may include the length of a side of a triangle and / or the width of a square or rectangle. The combination of the distal end 59 of the pointer 57 and the opening 130 may be configured such that the smallest second dimension D2 of the opening 130 is greater than the largest first diameter D1 of the distal end 59. As an advantage of using the surgical saw blade cartridges 110, 210 that define the reference features 156, 256, 356 based on the guide bars 111, 211 without using depressions or similar physical changes, the manufacturing process is simplified. In this example, only the opening 130 needs to be machined into the second plates 114, 214, and there is no need to further machine depressions into the third plates 116, 216. Machining depressions suitable for navigation confirmation and alignment is a costly and complex process. The spherical tip of the distal end 59 of the pointer 57 abuts against the flat portion of the third plates 114, 214. This abutment serves to define the plane of the third plates 116, 216 and thus the plane of the surgical saw blade cartridges 110, 210. Since there are holes in the second plates 114, 214 that provide access to the third plates 116, 216, the opening 130 functions as both a physical guide and a visual guide for the user to securely position the distal end 59 of the pointer 57 at the appropriate location on the third plates 116, 216, resulting in even higher accuracy. Since the opening 130 in the outer plates 112, 114, 212, 214 is a physical guide, it provides an excellent user experience that instills confidence in the alignment process. As described above, in a robotic system, mainly because accuracy of blade position and / or orientation in one plane, such as the y-plane in the main example, is required, this alignment function is sufficient.

[0120] Referring to FIGS. 6C and 6D, one of the alternative configurations of the reference feature 356 described above with respect to the surgical saw blade cartridges 110, 210 is shown. The reference feature 356 may be defined by markings such as laser markings or similar visual markers on the guide bar 111. As shown in FIGS. 6C and 6D, the reference feature 356 of the alternative configuration may include a visual marker disposed on at least one surface of the plates 112, 114, 116 of the guide bar 111. For example, the reference feature may include a visual mark disposed on the second plate 114 of the guide bar 111. The reference feature 356 may include a line that traces and / or delineates a portion of the tool mount 18, and by the pointer 57 tracing this line, the plane of the surgical saw blade cartridges 110, 210 is defined within the known coordinate system of the navigation system 32. In the drawings, an exemplary configuration of the path traced by the distal end 59 of the pointer 57 is shown by a dotted line, but it is also conceivable that the reference feature 356 is not physically and / or visually present on one of the plates 112, 114, 116 of the guide bar 111. For example, the process of aligning the surgical saw blade cartridges 110, 210 within the known coordinate system of the navigation system 32 may include tracing a path (similar to the path shown by the dotted line) along the intersection line of the tool mount 18 and the guide bar 111 having no defined visual or physical reference feature defined thereon.

[0121] Referring to FIGS. 7A-7D, one configuration of a tool mount 18 for securing either of the above-described surgical saw blade cartridges 110, 210 to a surgical instrument 14 is shown. The mount 18 may include a coupling rod 62 configured to removably secure the saw blade cartridges 110, 210 to the mount 18. The coupling rod 62 may interact with the openings 126, 152, 190, 226, 252, 290 of the saw blade cartridges 110, 210, such as keyhole openings 126, 226, to removably couple the saw blade cartridges 110, 210 to the mount 18. The coupling rod 62 may include a head configured to fit into a larger portion of the keyhole openings 126, 226, and the shaft of the coupling rod 62 may be configured to fit into a smaller portion of the keyhole openings 126, 226 after the head has been inserted through the larger portion. Thereafter, the larger portion may be seated above the smaller portion and configured to removably couple the saw blade cartridges 110, 210 to the mount 18. An exemplary configuration of a mount for a saw blade cartridge is disclosed in International Patent Application Publication No. WO2007 / 030793 and U.S. Patent No. 8,696,673, the entire contents of both of which are incorporated herein by reference.

[0122] The coupling rod 62 may be controlled by a coupling lever 64 configured to operate the coupling rod 62 between a locked state and an unlocked state. For example, the coupling lever 64 may be rotated in one direction to retract the coupling rod 62 into a locked state configured to secure the saw blade cartridges 110, 210 to the mount 18. Alternatively, the coupling lever 64 may be rotated in an opposite direction to extend or advance the coupling rod 62 into an unlocked state configured to enable attachment and / or removal of the saw blade cartridges 110, 210 to / from the mount 18.

[0123] Further, the mount 18 may include a horizontal mounting surface 66 configured to receive the saw blade cartridges 110, 210. When the saw blade cartridges 110, 210 are coupled to the mount, the lower surfaces of the proximal portions 118 of the first plates 112, 212 may be mounted adjacent to the mounting surface 66. When the coupling rod 62 is in the locked state, the coupling rod 62 may be configured to press the saw blade cartridges 110, 210 against the mounting surface 66 to hold the saw blade cartridges 110, 210 in place.

[0124] Further, the mount 18 may include a drive rod 76 for actuating the saw blades 170, 270 of the saw blade cartridges 110, 210. The drive rod 76 may include at least one drive pin 78 configured to be mounted in holes 166, 266 formed in the drive links 162, 262. Although a pair of drive pins 78 are shown in the drawings, it is also conceivable that the mount 18 may be configured to actuate the saw blades 170, 270 of the saw blade cartridges 110, 210 with only a single drive pin 78. During operation, the drive rod 76 may vibrate and / or partially rotate back and forth to reciprocate the drive pin 78 and reciprocate the drive links 162, 262.

[0125] Further, the drive rod 76 may include a biasing member (not shown) configured to bias the drive rod 76 in the proximal direction toward the lock position. The force of the biasing member can be overcome by pulling the drive rod 76 in the distal direction toward the mounting position. During operation, while the drive rod 76 is in the lock position, the holes 166, 266 formed in the drive links 162, 262 may be positioned above the drive pin 78. Then, when the saw blade cartridges 110, 210 are pulled in the distal direction (forward), the force of the biasing member is overcome, the drive rod is biased toward the mounting position, and the saw blade cartridges 110, 210 can be attached to the mount 18. When the saw blade cartridges 110, 210 are attached, that is, when the coupling rods are inserted into the keyhole openings 126, 226 and the proximal portions 118, 218 of the second plates 114, 214 are disposed adjacent to the mounting surface 66, the saw blade cartridges 110, 210 are released, and the biasing member moves the saw blade cartridges 110, 210 in the proximal direction until the lock position is reached.

[0126] The mount 18 may further include brackets 68 disposed on both sides of the lateral mounting surface 66. The brackets 68 may extend in the vertical direction (i.e., upward) from the lateral mounting surface 66, and the brackets 68 may include tabs 74 configured to at least partially extend over a portion of one side surface of the plates 112, 114, 116, 212, 214, 216 of the guide bars 111, 211 when the saw blade cartridges 110, 210 are coupled to the mount 18. For example, as shown in FIG. 7A, the proximal portion 118 of the guide bars 111, 211 may be configured such that one of the first plate 112 or the second plate 114 defines a recess 136 configured to expose a portion 134 of the third plate 116. The recess 136 of one of the first plate 112 or the second plate 114 is such that a portion 134 of the third plate 116 extends beyond the outer peripheral edge 136 of each of the first plate 112 or the second plate 114.

[0127] The purpose of pulling the saw blade cartridges 110, 210 distally (forward) to mount them on the mount 18 is to disengage the proximal portions 118, 218 of the saw blade cartridges 110, 210 from the tabs 74 of the bracket 68. Thereafter, when the biasing member moves the saw blade cartridges 110, 210 proximally, a portion of the proximal portions 118, 218 of the saw blade cartridges 110, 210 is seated between the tab 74 and the lateral mounting surface 66 of the mount 18.

[0128] In addition, the bracket 68 may define inner vertical surfaces 70, 72. The inner vertical surfaces 70, 72 may be oriented to provide a tapered vertical surface outward from the longitudinal axis of the mounting surface 66 at a later time. The tapered surface 325 may be configured to match various tapers of the opposing edges 140, 142, 240, 242 of the proximal portions 118, 218 of the guide bars 111, 211 for the purpose of orienting and / or fixing the saw blade cartridges 110, 210 relative to the mount 18. The tapered surfaces 70, 72 may be configured to match various tapers of the opposing edges 140, 142, 240, 242 of the proximal portions 118, 218 of the guide bars 111, 211, whereby a biasing member that biases the saw blade cartridges 110, 210 in the proximal direction pushes the proximal portions 118, 218 of the guide bars 111, 211 between the opposing tapered surfaces 70, 72 of the bracket 68 to axially align the surgical saw blade cartridges 110, 210 with respect to the surgical instrument 14. Also, it is conceivable that the proximal portions 118, 218 of the guide bars 111, 211 are pushed between the opposing tapered surfaces 70, 72 of the bracket 68 to laterally align the surgical saw blades 110, 210 with respect to the surgical instrument 14. The opposing edges 140, 142, 240, 242 of the proximal portions 118, 218 of the guide bars 111, 211 may be formed with various segments having different taper angles (described in more detail below), and the tapered surfaces 70, 72 of the bracket 68 formed to match therewith can improve the alignment of the saw blade cartridges 110, 210 relative to the mount 18 and can improve the accuracy of navigation of the saw blade cartridges 110, 210.

[0129] Alternatively, referring to FIG. 7B, it is also conceivable that only one of the opposing tapered surfaces 70, 72 of the bracket 68 may be configured to engage the opposing edges 140, 142, 240, 242 of the proximal portions 118, 218 of the guide bars 111, 211. As shown in FIGS. 7A and 7B, the opposing edges 140, 142, 240, 242 of the proximal portions 118, 218 of the guide bars 111, 211 may include a first segment 140, 240 and a second segment 142, 242. The first segments 140, 240 may be oriented at a first outward taper angle with respect to the longitudinal axis of the guide bars 111, 211, and the second segments 142, 242 may be oriented at a second outward taper angle with respect to the longitudinal axis of the guide bars 111, 211, and the first segments 140, 240 may be oriented at a first outward taper angle greater than the second outward taper angle of the second segments 142, 242. The first tapered surface 70 of the bracket 68 may be oriented at a third outward taper angle with respect to the longitudinal axis of the later mounting surface 66, and the second tapered surface 72 of the bracket 68 may be oriented at a fourth outward taper angle with respect to the longitudinal axis of the later mounting surface 66. The third outward taper angle of the first tapered surface 71 of the bracket 68 may be less than or equal to the fourth outward taper angle of the second tapered surface 72 of the bracket 68. Further, the third outward taper angle of the first tapered surface 70 of the bracket 68 is configured to match the first outward taper angle of the first segments 140, 240 of the opposing edges 140, 240 of the proximal portions 118, 218 of the guide bars 111, 211, and the first segments 140, 240 of the opposing edges 140, 240 of the proximal portions 118, 218 of the guide bars 111, 211 are adapted to be pushed between the first tapered surfaces 70 of the bracket 68. The matching tapers of the opposing edges 140, 240 of the proximal portions 118, 218 of the guide bars 111, 211 and the first tapered surface 70 of the bracket 68 may be configured as an alignment mechanism, whereby the guide bars 111, 211 may be axially aligned within the mount 18 by the engagement of the opposing edges 140, 240 of the proximal portions 118, 218 of the guide bars 111, 211 and the first tapered surface 70 of the bracket 68.Similarly, with respect to the fourth outer taper angle of the second taper surface 72 of the bracket 68, it may be configured to match the second outer taper angle of the first segment 142, 242 of the opposing edges 142, 242 of the proximal portions 118, 218 of the guide bars 111, 211, and may be configured to operate in the same manner as an alignment mechanism that axially aligns the guide bars 111, 211 within the mount 18. However, it is also conceivable that the proximal portion of the guide bar 111 may be configured such that the fourth outer taper angle of the second taper surface 72 of the bracket 68 is larger than the second outer taper angle of the first segment 142, 242 of the opposing edges 142, 242 of the proximal portions 118, 218 of the guide bars 111, 211, and a gap is formed between the taper surface 72 of the bracket 68 and the first segment 142, 242 of the proximal portions 118, 218 of the guide bars 111, 211. This configuration is shown in FIG. 7B. The configuration of the proximal portions 118, 218 of the guide bars 111, 211 may be utilized to avoid excessive restriction of the guide bars 111, 211 within the mount 18 and to avoid the occurrence of additional interference between the proximal portions 118, 218 of the guide bars 111, 211 and the mount 18 that may adversely affect the alignment of the guide bars 111, 211 within the mount 18.

[0130] During operation, the saw blade cartridges 110, 210 may be coupled to a surgical instrument 14 such as a robotic arm including a hand-held robotic instrument or a hand-held power tool. The saw blade cartridges 110, 210 may be fitted to the mount 18 of the surgical instrument 14. To achieve this, each drive pin 78 of the mount 18 is installed in holes 166, 266 formed in the drive links 162, 262 respectively, and the saw blade cartridges 110, 210 may be pulled forward by pulling the drive pin 78 and the driver mechanism 76 forward. Thereafter, the saw blade cartridges 110, 210 may descend such that the lower surfaces of the first plates 112, 212 are disposed adjacent to the mounting surface 66 of the mount 18. At this time, the coupling rod 62 of the mount 18 may be inserted through the overlapping openings 126, 152, 190, 226, 252, 290 of the saw blades 110, 210. Thereafter, the coupling rod 62 descends by the coupling lever 64, and the head of the coupling rod 62 descends onto the guide bars 111, 211, so that the head of the coupling rod 62 can press the upper surfaces of the plates 112, 114, 116, 212, 214, 216 including the keyhole-shaped openings 126, 226. By this pressing operation, the saw blade cartridges 110, 210 are held against the mount 18. When the saw blade cartridges 110, 210 are fixed to the mount 18, the drive pin 78 and the drive link 76 cooperate to bias the saw blade cartridges 110, 210 in the proximal direction. And the proximal portions 118, 218 of the saw blade cartridges 110, 210 are installed adjacent to the mount surface 66.

[0131] The saw blade cartridges 110, 210 may be actuated by the operation of a motor (not shown) of the surgical instrument 14. As a result of the operation of the motor, the drive pin 313 vibrates back and forth. Due to the movement of the drive pin 313, the drive links 162, 262 reciprocate back and forth in opposite directions. Due to the opposite back-and-forth movement of the drive links 162, 262, the saw blades 170, 270 pivot back and forth around the heads 158, 258 of the guide bars 111, 211. Due to the pivoting of the saw blades 170, 270, the blade heads 174, 274 and thus the blade teeth 176, 178, 276, 278 vibrate, so that the tissue against which the saw blade cartridges 110, 210 are pressed can be cut with the teeth.

[0132] Referring to FIGS. 8 - 13B, a third configuration of the blade cartridge 310 for use with the surgical instrument 14 of the surgical system of FIG. 1 is shown. It should be understood that the third configuration of the blade cartridge 310 may include some and / or all of the features of the blade cartridges 110, 210 described above. Further, it should be understood that the features of the blade cartridge 310 that include the same reference numbers may operate and / or function in the same manner as the components of the blade cartridges 110, 210 that include the same reference numbers.

[0133] The sagittal blade cartridge 310 may also be referred to as a sagittal blade cartridge, a surgical blade cartridge, or simply a cartridge. The blade cartridge 310 may include a guide bar 311. The guide bar 311 may include a plurality of plates 312, 314, 316 including a first plate 312, a second plate 314, and a third plate 316. The guide bar 311 may be configured such that the third plate 316 can be disposed between the first plate 312 and the second plate 314. For this reason, the first plate 312 may be referred to as the lower plate, the second plate 314 may be referred to as the upper plate, and the third plate 316 may be referred to as the inner plate, the central plate, the inner member, the central layer, and / or the central member. Although the guide bar 311 is shown as including only three plates laminated in a laminated arrangement, it is also conceivable that it may include any number of plates and / or layers.

[0134] As a whole, the plate is formed such that the guide bar 311 has a proximal portion 318 that constitutes the proximal ends of plates 312, 314, 116. The proximal portion 318 of the guide bar 311 may be configured to be initially tapered outwardly along the guide bar 311 in the distal direction and ultimately tapered inwardly along the guide bar 311 further in the distal direction. The outer taper of the proximal portion 318 of the guide bar 311 may be configured as an attachment feature to assist in the attachment and / or fixation of the saw blade cartridge 310 to a surgical instrument 14 such as a surgical robot or a handheld instrument. For example, as shown in FIGS. 10 and 11, the opposing outer edges of the proximal portion 318 of the guide bar 311 may define a contact surface with the tool mount 18. Further, one or both of the proximal portions 318 of the first and / or second plates 312, 314 may be shaped to define a recess 336 that exposes a portion 334 of the proximal portion 318 of the third plate 316 that is defined by the outer edge of the proximal portion 318 of the first and / or second plates 312, 314, or may be shaped to include a recess or notch 336. As shown in FIG. 10, the recess 336 may be sized and / or shaped to expose only a small portion 334 of the third plate, such as a tab 334 of the third plate 316 that is exposed by the recess 336 defined in the proximal portion 318 of the first plate 312. Alternatively, the recess 336 defined by the proximal portion of the first plate 312 may include the entire proximal portion 318 of the first plate 312 that is removed to expose the distal ledge of the third plate along the proximal edge of the proximal portion of the guide bar 311. In any configuration, the portion 334 of the proximal end 318 of the third plate 116 that is exposed by the recess 336 defined by the outer edge of the first or second plate 312, 314 may be configured as one of the portions 334 of the guide bar 311 that contacts and / or interacts with the mount 18 of the surgical instrument 14 for the attachment and / or alignment of the surgical blade cartridge 310 to the surgical instrument 14. This will be described in more detail below.

[0135] Referring to FIGS. 10 and 11, the opposing outer edges of the proximal portion 318 of the guide bar 311 may include a number of points 339, 341, 343 that are spaced along the outer peripheral edge of the proximal portion 318. Points 339, 341, 343 along the edges of the proximal portion 318 of the guide bar 311 may define a plurality of segments 340, 342 of the outer edge of the proximal portion 318 of the guide bar 311, each of which may have a different taper with respect to the longitudinal axis L extending from the proximal end 318 to the distal end 320 of the guide bar 311. The taper and / or orientation of each of the segments 340 of the opposing outer edges of the proximal portion 318 of the guide bar 311 may correspond and / or match the angle and / or taper of the surface of the bracket 68 of the mount 18 for securing the saw blade cartridge 310 to the surgical instrument 14, as will be described in more detail below.

[0136] The proximal portion 318 of the guide bar 311 may further include a proximal edge 344 that is oriented generally perpendicular to the longitudinal axis of the guide bar 311. A recess 328 may be defined in the proximal edge 344 of the guide bar 311. The recess 328 may be formed in the proximal edge 344 of the guide bar 311 on one side or the other side of the longitudinal axis L of the guide bar 311. The recess 328 may function as an aid for alignment and / or placement during the manufacture of the guide bar 311 (including the manufacture of the individual plates 312, 314, 316 that make up the guide bar). Further, it is contemplated that the recesses 328 formed in each of the first, second, and / or third plates 312, 314, 316 may differ in size and / or shape. For example, as shown in FIGS. 10 and 11, the recesses 328 formed in the first and third plates 312, 316 are deeply cut into the proximal portions of the respective plates and have a larger radius than the recess 328 formed in the second plate 314. This may enable the first and second plates 312, 314 to be distinguished during the manufacture of the guide bar 311, where otherwise the first and second plates 312, 314 would look very similar to each other. Also, the difference in size and / or shape of the recesses 128 formed in the first and second plates 312, 314 may assist the user in properly attaching the guide bar to the mount of the surgical instrument 14.

[0137] In front of the proximal portion 318 of the guide bar 311 are the central portion and the distal portion 320. The plates 312, 314, 316 are formed such that the opposing side portions of the guide bar that constitute the side portions of the central portion are generally parallel. In some configurations, the opposing side portions of the distal portion 120 of the guide bar 311 may be tapered. As shown in the drawings, the opposing edges 332, 399 of the distal portion 320 of the guide bar 311 may be tapered inwardly toward the center of the plates 312, 314, 316. Also, it is conceivable that the opposing edges of the distal portion 320 of the guide bar 311 may be generally parallel to each other. The width across the central portion and / or the distal portion 320 of the guide bar 311 may be smaller than the width of the proximal portion 318 at the widest point between the opposing edges of the proximal portion 318 of the guide bar 311.

[0138] The guide bar 311 may include a plurality of openings 330A, 330B, 330C, 330D, 330E, 330F corresponding to a plurality of reference features 356A, 356B, 356C, 356D, 356E, 356F so that the navigation system 32 can define the plane of the surgical saw blade cartridge 310. However, additional openings 330A, 330B, 330C, 330D, 330E, 330F and corresponding reference features 356A, 356B, 356C, 356D, 356E, 356F may be defined on the guide bar 311. The openings 330A, 330B, 330C, 330D, 330E, 330F may be arranged to provide access to the reference features 356A, 356B, 356C, 356D, 356E, 356F defined on the inner plate 316. Alternatively, the openings 330A, 330B, 330C, 330D, 330E, 330F themselves defined by the first and / or second plates 312, 314 may define the reference features 356A, 356B, 356C, 356D, 356E, 356F of the guide bar 311.

[0139] The openings 330A, 330B, 330C, 330D, 330E, 330F and the corresponding reference features 356A, 356B, 356C, 356D, 356E, 356F may be arranged spaced apart from each other on the guide bar 311 so that a straight line cannot be drawn intersecting all of the reference features 356A, 356B, 356C, 356D, 356E, 356F of the individual plates 312, 314, 316. As shown in FIGS. 8 to 13B, the reference features 356 may be arranged generally triangularly on any of the plates 312, 314, 316 of the guide bar. Further, as shown in FIGS. 8 to 13B, the openings 330A, 330B, 330C, 330D, 330E, 330F and / or the reference features 356A, 356B, 356C, 356D, 356E, 356F defined on the plates 312, 314, 316 are such that when the plates 312, 314, 316 are assigned as the guide bar 311, each of the openings 330A, 330B, 330C, 330D, 330E, 330F and / or each of the reference features 356A, 356B, 356C, 356D, 356E, 356F of one plate 312, 314, 316 is concentrically aligned with the openings 330A, 330B, 330C, 330D, 330E, 330F and / or the reference features 356A, 356B, 356C, 356D, 356E, 356F of another plate 312, 314, 316, and may be arranged on each of the plates 312, 314, 316.

[0140] Furthermore, it is also conceivable that the guide bar 311 can be configured to define openings 330A, 330B, 330C, 330D, 330E, 330F and / or reference features 356A, 356B, 356C, 356D, 356E, 356F on at least two different surfaces of the plates 312, 314, 316. This may include defining the openings 330A, 330B, 330C, 330D, 330E, 330F and / or reference features 356A, 356B, 356C, 356D, 356E, 356F on both sides of a single plate such as the third plate 316. Alternatively, it may include defining the openings 330A, 330B, 330C, 330D, 330E, 330F and / or reference features 356A, 356B, 356C, 356D, 356E, 356F on the surfaces of two different plates 312, 314, 316. For example, as shown in FIGS. 8-12, the guide bar 311 may be configured such that the openings 330A, 330B, 330C, 330D, 330E, 330F and / or reference features 356A, 356B, 356C, 356D, 356E, 356F are defined on the surfaces of the first plate 312 and the second plate 314, respectively. By collecting reference points, it may be configured to align the guide bar 311 within a known coordinate system of the navigation system and / or to confirm proper attachment of the guide bar within the surgical manipulator 14.

[0141] The reference features 356A, 356B, 356C, 356D, 356E, 356F and thus the openings 330A, 330B, 330C, 330D, 330E, 330F may be arranged on the guide bar 311 not only at known positions relative to specific positions of the reference features 356A, 356B, 356C, 356D, 356E, 356F on the guide bar 311, but also at positions of each other reference feature 356A, 356B, 356C, 356D, 356E, 356F relative to each of the reference features 356A, 356B, 356C, 356D, 356E, 356F. The known positions of the reference features 356A, 356B, 356C, 356D, 356E, 356F on the guide bar 311 are utilized for defining the positions of the guide bar 311 and / or the surgical saw blade cartridge 310 within a known coordinate system of the navigation system 32. The known positions of the reference features 356A, 356B, 356C, 356D, 356E, 356F are utilized by the navigation system 32 to calculate the expected positions of each reference feature 356A, 356B, 356C, 356D, 356E, 356F based on the geometric characteristics and mechanical stack-up of each of the surgical instrument 14 and the surgical saw blade cartridge 310 as part of the alignment process, as will be described in more detail below.

[0142] The reference feature 356 may be defined as a recess, indentation, depression, mark, or similar marking in any of the plates 312, 314, 316 of the guide bar 311. This may include a depression on the surface of any of the plates 312, 314, 316. Further, the reference feature 356 may conceivably include markings such as laser markers defined in any of the plates 312, 314, 316 (without any physical recesses, depressions, or openings). The marking may be realized as a notch, color, engraving, or similar optical marking.

[0143] Referring to FIGS. 13A and 13B, an exemplary configuration of two separate distal ends 59 of the pointer 57 with respect to the reference features 356A, 356B, 356C, 356D, 356E, 356F defined on the guide bar 311 and / or the openings 330A, 330B, 330C, 330D, 330E, 330F is shown. The distal ends 59 of the pointer 57 are sized and / or shaped to fit within the openings 330 defined in the first or second plates 312, 314 of the guide bar 311 as described above so that contact with the reference feature 356 disposed on the third plate 316 is not inhibited and / or prevented. For example, as shown in FIG. 13A, a first configuration of the distal end 59 of the pointer 57 includes a spherical tip of a first diameter D1. The opening may have a second dimension D2. The second dimension D2 may define the diameter of a circular or elliptical opening. Alternatively, the second dimension D2 may include the length of a side of a triangle and / or the width of a square or rectangle. The combination of the distal end 59 of the pointer 57 and the opening 330 may be configured such that the smallest second dimension D2 of the opening 330 is larger than the largest first diameter D1 of the distal end 59. As an advantage of using the surgical saw blade cartridges 310, 210 that define the reference feature 356 without using a depression or similar physical change to the guide bar 311, the manufacturing process is simplified. In this example, only the opening 330 needs to be machined into the second plate 314, and there is no need to further machine a depression into the third plate 316. Machining a depression suitable for navigation confirmation and alignment is a costly and complex process. The spherical tip of the distal end 59 of the pointer 57 abuts against the flat portion of the third plate 316. This abutment helps in aligning the surgical blade within the known coordinate system of the navigation system.

[0144] Alternatively, the distal end 59 of the pointer 57 may be sized and / or shaped to be larger than the opening 330 defined in the first or second plate 312, 314 of the guide bar 311 such that contact with the third plate 316 is inhibited and / or prevented. In this configuration of the guide bar 311, the opening 330 is configured to function as a reference feature 356, and the distal end 59 of the pointer 57 is sized and / or configured to contact the opening 330. For example, as shown in FIG. 13B, a first configuration of the distal end 59 of the pointer 57 includes a spherical tip having a third dimension D3 that is larger than a second dimension D2 of the opening 330. As shown in FIG. 13B, the distal end 59 of the pointer 57 can be operated to contact the opening 330 defined in the first and / or second plate 312, 314 without contacting the third plate 316. Also, the first and / or second plate 312, 314 may define a reference 356 such as a recess, indentation, etc. that the distal end 59 of the pointer 57 contacts for alignment of the blade with the navigation system.

[0145] Referring to FIGS. 14 - 17, a third configuration of the surgical blade 310B including an alternative arrangement of the reference feature 356 defined by the plates 312, 314, 316 is shown. As shown in FIGS. 14 - 17, the reference feature 356 may be arranged generally triangularly on any of the respective plates 312, 314, 316 of the guide bar. Further, as shown in FIGS. 14 - 17, the openings 330A, 330B, 330C, 330D, 330E, 330F and / or the reference features 356A, 356B, 356C, 356D, 356E, 356F defined on the plates 312, 314, 316 are such that when the plates 312, 314, 316 are assembled as the guide bar 311, each of the openings 330A, 330B, 330C, 330D, 330E, 330F and / or each of the reference features 356A, 356B, 356C, 356D, 356E, 356F of a certain plate 312, 314, 316 is concentrically aligned with the openings 330A, 330B, 330C, 330D, 330E, 330F and / or the reference features 356A, 356B, 356C, 356D, 356E, 356F of another plate 312, 314, 316. In the configuration of the surgical blade 310B, the most distal openings 330A, 330D and / or the reference features 356A, 356D defined on the guide bar 311 are arranged in the distal direction on the guide bar 311 with respect to the most distal openings 330A, 330D and / or the reference features 356A, 356D of the blade cartridge 310A of FIGS. 8 - 12.

[0146] Referring to FIGS. 18 - 23B, a fourth configuration of the blade cartridge 410 for use with the surgical instrument 14 of the surgical system of FIG. 1 is shown. The blade cartridge 410 may include some or all of the features of any of the configurations of the blade cartridges 110, 210, 310 described above. Further, it should be understood that the features of the blade cartridge 410 having the same reference numbers may operate and / or function in the same manner as the components of the blade cartridges 110, 210, 310 having the same reference numbers.

[0147] The blade cartridges 410 shown in FIGS. 18-22 typically include all of the features of the third configuration of the blade cartridge 410 and have an alternative arrangement of the reference feature portion 456 defined by the plates 412, 414, 416. As shown in FIGS. 18-22, the openings 430 and / or the reference feature portion 456 may be arranged generally rectangularly or trapezoidally on any of the plates 412, 414, 416 of the guide bar 411. Further, as shown in FIGS. 18-22, the openings 430A, 430B, 430C, 430D, 430E, 430F, 430G, 430H and / or the reference feature portions 456A, 456B, 456C, 456D, 456E, 456F, 456G, 456H defined on the plates 412, 414, 416 are such that when the plates 412, 414, 416 are assembled as the guide bar 411, each of the openings 430A, 430B, 430C, 430D, 430E, 430F, 430G, 430H and / or each of the reference feature portions 456A, 456B, 456C, 456D, 456E, 456F, 456G, 456H of a certain plate 412, 414, 416 is concentrically aligned with the openings 430A, 430B, 430C, 430D, 430E, 430F, 430G, 430H and / or the reference feature portions 456A, 456B, 456C, 456D, 456E, 456F, 456G, 456H of another plate 412, 414, 416.

[0148] Referring to FIGS. 24-37, various methods of alignment and / or verification are shown in the form of flowcharts. Hereinafter, the various alignment and / or verification processes will be described in more detail.

[0149] Alignment Process

[0150] When the saw blade cartridges 110, 210, 310, 410 are attached to the mount 18 and / or the surgical instrument 14, the reference features 156, 256, 356, 456 of the saw blade cartridges 110, 210, 310, 410 may be utilized to align and / or verify the posture of the saw blade cartridges 110, 210, 310, 410 using the navigation system 32. Referring again to FIGS. 6A-6D, various configurations of the system for aligning the surgical saw blade cartridge 110 coupled to the surgical instrument 14 are shown.

[0151] Aligning the surgical saw blade cartridges 110, 210, 310, 410 within a known coordinate system defined by the navigation system 32 may include determining the expected positions of the reference features 156, 256, 356, 456 based on predetermined geometric data corresponding to the relationship between the mounting features and the reference features 156, 256, 356, 456 of the saw blade cartridges 110, 210 as described above. The expected positions may be calculated and / or determined by the navigation system 32 based on known geometric data regarding the surgical instrument 14, the mount 18, and / or the surgical saw blade cartridges 110, 210, 310, 410 and the posture of the tracker 52 disposed on the surgical instrument 14. Using the known geometric data or the posture of the various components and the tracker 52 disposed on the surgical instrument 14, the navigation system may compute a transformation to determine the expected positions of the reference features 156, 256, 356, 456.

[0152] A method of aligning the surgical saw blade cartridges 110, 210 within a known coordinate system may further include determining the actual positions of the surgical saw blade cartridges 110, 210, 310, 410 within the known coordinate system defined by the navigation system 32. The pointer 57 may be utilized to determine the actual positions of the surgical saw blade cartridges 110, 210, 310, 410 within the known coordinate system. This step may include contacting the pointer 57 or an instrument including the pointer tracker PT against one or more of the reference features 156, 256, 356, 456 defined and / or disposed on the guide bars 111, 211, 311, 411. For example, in one configuration of the surgical saw blade cartridge 110 described above, the guide bar 111 may include an opening 130 defined in one or both of the plates 112, 114 of the guide bar 111 and providing access to the reference feature 156 disposed on the inner plates 116, 216. In this configuration, contacting the pointer 57 against the reference feature 156 may include inserting and / or passing the distal end 59 of the pointer 57 through the opening 130 defined in at least one of the first plate 112, 212 or the second plate 114, 214 to contact the reference feature 156. The navigation system 32 may track the orientation of the pointer 57 via the pointer tracker PT when the pointer 57 is operated to contact each of the reference features 156. While the distal end 59 of the pointer is engaged with the reference feature 156, the navigation system may be configured to determine the actual position of each of the reference features 156 within the known coordinate system by calculating the transformation using the orientation of the pointer 57 within the known coordinate system.

[0153] Alternatively, according to a second configuration of the surgical saw blade cartridge 210 in which the reference feature 256 is defined on one of the surfaces of the first or second plate 212, 214, the step of determining the actual position of the surgical saw blade cartridge 210 within a known coordinate system may include operating the pointer 57 so that the distal end 59 of the pointer 57 contacts each of the reference features 256. The navigation system 32 may track the orientation of the pointer 57 via the pointer tracker PT when the pointer 57 is operated so as to contact each of the reference features 256. While the distal end 59 of the pointer 57 is engaged with the reference feature 256, the navigation system 32 may be configured to determine the actual position of each of the reference features 256 within the known coordinate system by calculating a transformation using the orientation of the pointer 57 within the known coordinate system.

[0154] In yet another configuration, the step of determining the actual position of the surgical saw blade cartridge 110 within a known coordinate system may include operating the pointer 57 so that the distal end 59 of the pointer 57 traces a reference feature 356 defined on the guide bar 111. The navigation system 32 may track the orientation of the pointer 57 via the pointer tracker PT when the pointer 57 is operated to trace along a path that defines the reference feature 356. For example, the reference feature may include a path that at least partially depicts a contour of a portion of the outer periphery of the mount 18 on the surface of the guide bar 111 (see FIGS. 6C and 6D). When the distal end 59 of the pointer 57 is tracing a path that defines the reference feature 356, the navigation system 32 may use the orientation of the pointer 57 within the known coordinate system to calculate a transformation, in a known coordinate system such as the coordinate system of the tracker 52, to determine the actual orientation of the plane of the surgical saw blade cartridge 110, and more specifically, the orientation of a plane defined by one or more of the first, second, and third plates 112, 114, 116.

[0155] To determine the actual orientation of the plane of the cartridge, the navigation system may determine the actual positions of the reference features 156, 256, 356 defined and / or disposed on the guide bars 111, 211, 311, 411. The navigation system 32 may be further configured to compare the actual positions of each of the reference features 156, 256, 356 found (i.e., with respect to the localizer) by use of the pointer 57 against the expected positions of each of these reference features based on the stored information of the positions of the reference features 156, 256, 356, 456 relative to the tracker 52 determined during manufacture. This comparison may include calculating the deviation between the actual positions of each of the reference features 156, 256, 356 found by use of the pointer 57 and the expected positions of each of the reference features 156, 256, 356, 456 based on the stored information. For example, the deviation between the actual positions of each of the reference features 156, 256, 356, 456 found by use of the pointer 57 and the expected positions of each of the reference features 156, 256, 356, 456 may be determined by use of a least squares model.

[0156] Using the calculated deviation between the actual positions of each of the reference features 156, 256, 356, 456 found by use of the pointer 57 and the expected positions of each of the reference features 156, 256, 356, 456, the navigation system 32 may be further configured to adapt the positions of each of the reference features 156, 256, 356, 456 within a known coordinate system and to assign a hybrid position to each of the reference features 156, 256, 356, 456 based on the calculated deviation. This hybrid position will define the positions of each of the reference features 156, 256, 356, 456 at an intermediate position between the actual positions of each of the reference features 156, 256, 356, 456 found by use of the pointer 57 and the expected positions of each of the reference features 156, 256, 356 (e.g., with respect to the tracker 52 on the surgical instrument 14) within a known coordinate system.

[0157] This method may further include defining the planes of the guide bars 111, 211, 311, 411 and / or the surgical saw blade cartridges 110, 210, 310, 410 relative to the tracker 52 on the surgical instrument 14 using the hybrid positions assigned to the respective reference features 156, 256, 356, 456 within a known coordinate system. The navigation system 32 may be further configured to navigate the surgical instrument 14 and thus the surgical saw blade cartridges 110, 210, 310, 410 during the surgical procedure. This may be achieved by tracking the position and / or orientation of the tracker 52 on the surgical instrument 14. When the surgical saw blade cartridges 110, 210, 310, 410 are aligned relative to the tracker 52 on the surgical instrument 14 within a known coordinate system, the navigation system 32 will be able to determine the orientation of the surgical saw blade cartridges 110, 210, 310, 410 based on the position of the tracker 52 on the surgical instrument 14 within the known coordinate system.

[0158] The alignment technique of using the hybrid position to define the plane of the cartridge in this way provides a fast and effective alignment method for a saw blade system that does not control all six degrees of freedom of the position of the cartridge, such as a robotic system that only performs three degrees of freedom of control as described in PCT / US2021 / 049440 (the entire content of which is incorporated herein by reference). In the case of a handheld robotic system, the position of the saw blade relative to the bone may not be controlled in all degrees of freedom by the actuator, such as with respect to the depth of the saw blade relative to the tool platform. In the case of such a handheld robotic system, it is not necessary to be able to determine the distal end of the saw cartridge, i.e., the blade, with absolute accuracy.

[0159] In yet another configuration, a method of aligning the saw blades 110, 210, 310, 410 within a known coordinate system of a navigation system includes attaching the surgical saw blades 110, 210, 310, 410 to a surgical manipulator including a first tracking device; contacting at least two reference features 156, 256, 356, 456 respectively on a first surface or plate 112, 212, 312, 412 of the surgical saw blades 110, 210, 310, 410 with a distal end of a surgical instrument including a second tracking device; contacting at least two reference features 156, 256, 356, 456 respectively on a second surface or plate 114, 214, 314, 414 of the surgical saw blades 110, 210, 310, 410 with the distal end of the surgical instrument; contacting at least one reference feature 60 on the surgical manipulator; tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system when the distal end of the surgical instrument is in contact with the reference features 156, 256, 356, 456 of the surgical saw blade and the surgical manipulator respectively to define the actual positions of the reference features 156, 256, 356, 456 of the surgical saw blade relative to the reference feature of the surgical manipulator; and defining the hybrid position of each of at least one reference feature 60 of the surgical manipulator by performing a mathematical fit between the actual positions of the reference features 156, 256, 356, 456 of the surgical saw blades 110, 210, 310, 410 and at least one reference feature 60 of the surgical manipulator.

[0160] Also, a method of aligning the saw blades 110, 210, 310, 410 within a known coordinate system may include defining the hybrid position of at least one reference feature of the surgical manipulator within the known coordinate system based on the mathematical fit such that the hybrid position of each reference feature differs from the actual position by only one degree of freedom.

[0161] Also, a method of aligning the saw blades 110, 210, 310, 410 within a known coordinate system may include the step of moving the actual position of each of at least one reference feature of the surgical manipulator by only one degree of freedom by defining a hybrid position of at least one reference feature of the surgical manipulator within the known coordinate system based on a mathematical fit.

[0162] Also, in the method of aligning the saw blades 110, 210, 310, 410 within a known coordinate system, the one degree of freedom is along the longitudinal axis of the surgical saw blades 110, 210, 310, 410.

[0163] In yet another embodiment, a method of aligning the surgical saw blades 110, 210, 310, 410 within a known coordinate system of a navigation system includes attaching a surgical saw blade to a surgical manipulator including a first tracking device, contacting each of at least two reference features on a first surface of the surgical saw blade with a distal end of a surgical instrument including a second tracking device, contacting each of at least two reference features on a second surface of the surgical saw blade with the distal end of the surgical instrument, tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system when the distal end of the surgical instrument is in contact with each of the reference features on the first surface and the second surface of the surgical saw blade to define the actual positions of each of the reference features of the first surface and the second surface relative to the first tracking device of the surgical manipulator, and defining the position and / or orientation of the surgical saw blade within the known coordinate system in one or more degrees of freedom based on a mathematical fit of the positions of at least two reference features of each of the first surface and the second surface.

[0164] Also, a method of aligning the saw blades 110, 210, 310, 410 within a known coordinate system may include contacting a manipulator reference feature defined on a surgical manipulator with a distal end of a surgical instrument, and defining a hybrid position of the manipulator reference feature within the known coordinate system based on a comparison of the actual positions of the reference features of the first surface and the second surface relative to the manipulator reference feature. The tool center point may be further defined based on a mathematical fit of the positions of at least two reference features of each of the first surface and the second surface and the hybrid position of the manipulator reference feature. The tool center point may represent the origin of a reference array specific to the surgical saw blades 110, 210, 310, 410, or may be considered to represent the origin of a reference array of a system including at least the surgical saw blades 110, 210, 310, 410 and the surgical manipulator 14.

[0165] Verification process

[0166] The combination of three or more openings 130A, 130B, 130C and three or more reference features 156A, 156B, 156C may be further configured to confirm the position and / or orientation of the surgical saw blades 110, 210 relative to the tracker 52 of the surgical instrument 14 within a known coordinate system defined by the navigation system 32. Of course, the dimensions of the openings 130A, 130B, 130C and the corresponding reference features 156A, 156B, 156C may have a predetermined dimensional relationship to one or more mounting features. Thereby, by contacting the distal end 59 of the pointer 57 against one or more of the reference features 156A, 156B, 156C disposed on the guide bar 111, the aforementioned alignment and / or confirmation within the known coordinate system of the surgical navigation system 32 can be completed. For example, the predetermined dimensional relationship may be stored in the memory unit of the surgical navigation system 32 based on the geometric characteristics of the combination of the surgical saw blade cartridges 110, the mount 18, and the surgical instrument 14. Based on these known geometric characteristics, the navigation system may be configured to determine the expected position of each of the reference features 156A, 156B, 156C of the guide bar relative to the tracker 52 of the surgical instrument 14.

[0167] To complete the confirmation process, the pointer 57 can be manipulated to contact one or more of the fiducial features 156A, 156B, 156C while the navigation system 32 tracks the orientation of the pointer 57 via the pointer tracker PT. The navigation system 32 may be configured to define the actual position of each of the fiducial features 156A, 156B, 156C in a known coordinate system based on the orientation of the pointer 57 when in contact with each of the fiducial features 156A, 156B, 156C. Also, the predicted position of each of the fiducial features 156A, 156B, 156C may be compared to the actual position of the fiducial features 156A, 156B, 156C. The navigation system 32 may be configured to define an allowable deviation amount between the predicted position and the actual position of each of the fiducial features 156A, 156B, 156C. If the deviation between the predicted position and the actual position of each of the fiducial features 156A, 156B, 156C is the allowable deviation amount, the navigation system 32 may be configured to permit the operation and / or navigation of the surgical instrument 14 during the surgical procedure. On the other hand, if the deviation between the predicted position and the actual position of each of the fiducial features 156A, 156B, 156C is greater than the allowable deviation amount, the navigation system 32 may be configured to provide an alert to the user and / or prevent the operation and / or navigation of the surgical instrument 14.

[0168] Also, a similar confirmation process may be completed for one of the alternative configurations of the surgical saw blade cartridges 110, 210, 310, 410 that includes one of another type of fiducial features 156, 256, 356, 456, such as laser marking and / or tracing of patterns or contours on the guide bars 111, 211, 311, 411.

[0169] Also, a combination of the openings 130, 230, 330, 430 and / or the reference features 156, 256, 356, 456 defined by the guide bars 111, 211, 311, 411 may be configured to confirm whether the surgical saw blade cartridges 110, 210, 310, 410 are properly mounted. During operation, this method may include the step of manipulating the pointer 57 to contact one or more of the reference features 156, 256, 356, 456 while the navigation system 32 tracks the posture of the pointer 57 via the pointer tracker PT. The navigation system 32 may be configured to define the actual position of each of the reference features 156, 256, 356, 456 in a known coordinate system based on the posture of the pointer 57 when in contact with each of the reference features 156, 256, 356, 456. Also, the pointer 57 may be manipulated to contact one or more of the manipulator reference features 60 while the navigation system 32 tracks the posture of the pointer 57 via the pointer tracker PT. The navigation system 32 may be configured to define the actual position of the manipulator reference features 60. This method may further include applying a mathematical fit to the actual positions of the reference features 156, 256, 356, 456 relative to the actual position of the manipulator reference features 60, and based on a comparison of the actual position of the manipulator reference features relative to the actual positions of the reference features of the first and second surfaces, determining whether the blade cartridges 110, 210, 310, 410 are properly attached to the surgical manipulator based on the defined deviation being within an acceptable threshold / range.

[0170] Also, the combination of the openings 130, 230, 330, 430 and / or the reference features 156, 256, 356, 456 defined by the guide bars 111, 211, 311, 411 may be configured to confirm that the process of aligning the surgical saw blade cartridges 110, 210, 310, 410 by the navigation system has been successfully completed. Further, this method includes attaching a surgical saw blade cartridge including a guide bar having a first plate disposed adjacent to a second plate and a blade at least partially disposed between the first plate and the second plate and extending from a distal end of the guide bar to a surgical manipulator including a first tracking device. Further, this method includes contacting at least two reference features on the first plate of the guide bar with the distal end of a surgical instrument including a second tracking device, and contacting at least two reference features on the second plate of the guide bar with the distal end of the surgical instrument, wherein the reference features of the first plate are each concentric with one of the reference features of the second plate. Further, during contact with the reference features, when the distal end of the surgical instrument is in contact with the reference features on the first plate and the second plate of the surgical saw blade cartridge, the position of the first tracking device and the second tracking device is tracked by the localizer of the navigation system to define the actual positions of the reference features of the first plate and the second plate relative to the first tracking device of the surgical manipulator. And this method may include determining the thickness of the cartridge based on the actual positions of the reference features on the first plate and the second plate, and providing an indication to the user based on the determined thickness of the cartridge.

[0171] The various shapes of the elements may be different from those described above.

[0172] Accordingly, the purpose of the appended claims is to cover all such variations and modifications as described above, including the true spirit and scope of the surgical saw blade cartridges 110, 210, 310, 410.

Claims

Claim 1 A saw blade cartridge for use with a surgical device, comprising: a first plate and a second plate, each having a distal portion and a proximal portion; an inner plate disposed at least partially between the first plate and the second plate and defining a pivot surface; a guide bar having; a blade disposed at least partially between the first plate and the second plate, the blade having a blade body including a proximal end and a distal end; a blade head disposed at the distal end of the blade body and having teeth formed thereon; and a blade, wherein the proximal end of the blade body abuts against the pivot surface; and wherein the proximal portions of the first plate and the second plate each define an outer peripheral edge; a saw blade cartridge, wherein a portion of the inner plate extends beyond the outer peripheral edge defined by at least one of the proximal portions of the first plate and the second plate. Claim 2 The saw blade cartridge according to claim 1, wherein the outer peripheral edge defined by at least one of the proximal portions of the first plate and the second plate is disposed over the entire portion of the inner plate that extends beyond the at least one of the proximal portions of the first plate and the second plate, and defines a shelf portion that assists in attaching and aligning the saw blade cartridge to the surgical device. Claim 3 The saw blade cartridge according to claim 1, wherein the outer peripheral edge defined by only one of the proximal portions of the first plate and the second plate is disposed over the entire portion of the inner plate that extends beyond the other of the at least one of the proximal portions of the first plate and the second plate, and defines a shelf portion that assists in attaching and aligning the saw blade cartridge to the surgical device. Claim 4 The saw blade cartridge according to claim 1, wherein the outer peripheral edge defined by at least one of the proximal portions of the first plate and the second plate comprises a recess that exposes the portion of the inner plate and defines a shelf portion that assists in attaching and aligning the saw blade cartridge to the surgical device. Claim 5 The outer peripheral edge defined by only the proximal portion of either the first plate or the second plate exposes a part of the inner plate and defines a recess that aids in the attachment and alignment of the saw blade cartridge to the surgical device. The saw blade cartridge according to claim 1.

6. The saw blade cartridge according to any one of claims 1 to 5, wherein the first plate defines a keyhole shape for attaching the blade, and the inner plate extends beyond the outer peripheral edge defined by the second plate.

7. The saw blade cartridge according to any one of claims 1 to 5, wherein the inner plate defines a recess on a side surface of the inner plate facing the opposite of the longitudinal axis of the cartridge, and the first plate defines a recess aligned with the recess of the inner plate.

8. The saw blade cartridge according to any one of claims 1 to 5, wherein the inner plate further includes teeth that extend from the proximal end of the guide bar and define the pivoting surface.

9. The saw blade cartridge according to claim 8, wherein the teeth are inner teeth, the inner plate further includes a first outer tooth and a second outer tooth, and the inner teeth are disposed between the first outer tooth and the second outer tooth.

10. The saw blade cartridge according to claim 8, wherein the teeth are inner teeth, the inner plate further includes a first outer tooth and a second outer tooth disposed between the first plate and the second plate, and the inner teeth are disposed between the first outer tooth and the second outer tooth.

11. The saw blade cartridge according to claim 9 or 10, wherein the first outer tooth and the second outer tooth extend further toward the distal end of the guide bar than the inner teeth.

12. The first outer tooth and the second outer tooth each include a distal end, The guide bar is configured such that the distal ends of the first outer tooth and the second outer tooth are located proximal to the distal ends of the first plate and the second plate. The side surfaces defined by the first plate and the second plate are proximal to the distal ends of the first plate and the second plate and distal to the distal ends of the first outer tine and the second outer tine respectively, defining an opening that enables the discharge of foreign matter, the saw blade cartridge according to claim 9 or 10.

13. The first outer tine and the second outer tine each have a distal tip, The guide bar is configured such that the distal tips of the first outer tine and the second outer tine respectively are adjacent to the distal ends of the first plate and the second plate, the saw blade cartridge according to claim 10.

14. The pivoting surface is an arcuate surface, the saw blade cartridge according to any one of claims 1 to 13.

15. The proximal end of the blade body defines a recess that abuts against the pivoting surface, and the blade body is configured to pivot around the pivoting surface defined by the inner plate when the blade body is in operation, the saw blade cartridge according to claim 14.

16. The teeth define a thickness of the blade head that is greater than or equal to the thickness of the guide bar, and the guide bar can be inserted into the cut made by the blade head, the saw blade cartridge according to claim 14 or 15.

17. At least one of the plates defines a reference feature configured to facilitate determination of the position and / or orientation of the surgical blade by a navigation system, the saw blade cartridge according to any one of claims 1 to 16.

18. The reference feature is selected from the group including an optical marking, a depression, or an opening, the saw blade cartridge according to claim 17.

19. The saw blade cartridge further comprises at least one drive link movably disposed between the first plate and the second plate, The at least one drive link has opposing proximal and distal ends, the proximal end being adapted to be attached to a drive element of the surgical device, and the distal end being connected to the proximal end of the blade body such that the blade pivots about the pivot plane by a reciprocating motion of the at least one drive link. The saw blade cartridge according to any one of claims 1 to 18.

20. The saw blade cartridge according to claim 19, wherein the at least one drive link includes at least two drive links.

21. The saw blade cartridge according to claim 20, wherein the at least two drive links are movably coupled to the blade head.

22. A saw blade cartridge for a surgical device, a guide bar, a first plate and a second plate each having a distal portion and a proximal portion, an inner plate disposed partially between the first plate and the second plate, having, a guide bar that defines a pivot plane, a blade disposed at least partially between the first plate and the second plate, a blade body including a proximal end and a distal end, a blade head disposed at the distal end of the blade body and having teeth formed thereon, having, a blade, wherein the proximal end of the blade body abuts against the pivot plane, comprising, wherein the proximal portions of each of the first plate and the second plate respectively define an outer peripheral edge, A saw blade cartridge, wherein a portion of the inner plate extends beyond the outer peripheral edge defined by at least one of the proximal portions of the first plate and the second plate.

23. A saw blade cartridge for a surgical device and a navigation system, a guide bar including a distal portion and a proximal portion, a first plate, a second plate, an inner plate disposed between the first plate and the second plate, having, a guide bar, a blade disposed at least partially between the first plate and the second plate of the guide bar, a blade body including a proximal end that abuts against a pivot plane defined by the guide bar and a distal end, a blade head disposed at the distal end of the blade body and having teeth formed thereon, A blade having, At least three landmarks disposed on an outer surface of one of the first plate or the second plate, the landmarks defining a plane of the guide bar within the coordinate system of the navigation system A saw blade cartridge comprising.

24. The saw blade cartridge according to claim 23, wherein each of the at least three landmarks is defined on one of the first plate or the second plate and includes optical markings that facilitate determination of the position and / or orientation of the surgical blade by a navigation system.

25. The saw blade cartridge according to claim 23 or 24, wherein the blade head further defines a notch including an opening defined between two adjacent teeth.

26. The saw blade cartridge according to claim 25, wherein the notch defines a teardrop-shaped opening in the blade head.

27. The proximal portions of the first plate and the second plate each define an outer peripheral edge, The saw blade cartridge according to any one of claims 23 to 26, wherein a part of the proximal portion of the inner plate extends beyond the outer peripheral edge defined by at least one of the proximal portions of the first plate and the second plate.

28. A saw blade cartridge for a surgical device and a navigation system, A guide bar including a distal portion and a proximal portion, A first plate, A second plate, An inner plate disposed partially between the first plate and the second plate and defining a pivoting surface, A guide bar having, A blade disposed at least partially between the first plate and the second plate, A blade body including a proximal end that abuts the pivoting surface and a distal end, A blade head disposed at the distal end of the blade body and having teeth formed thereon, A blade having, At least three openings defined in one of the first plate or the second plate, the at least three openings providing access to the outer surface of the inner plate at each position of the at least three openings, A saw blade cartridge comprising.

29. The proximal portions of the first plate and the second plate each define an outer peripheral edge, The saw blade cartridge according to claim 28, wherein a part of the proximal portion of the inner plate extends beyond the outer peripheral edge defined by at least one of the proximal portions of the first plate and the second plate.

30. A saw blade cartridge for a surgical device, a guide bar including a distal end and a proximal end, a first plate, a second plate, an inner plate partially disposed between the first plate and the second plate and defining a pivoting surface, a guide bar having a recess defined at the proximal end of at least one of the first plate, the second plate, or the inner plate, a blade at least partially disposed between the first plate and the second plate, a blade body including a proximal end and a distal end that abuts against the pivoting surface, a blade head disposed at the distal end of the blade body and having teeth formed thereon, a blade having a saw blade cartridge comprising.

31. The saw blade cartridge according to claim 30, wherein the blade head further defines a notch including an opening defined between two adjacent teeth.

32. The saw blade cartridge according to claim 30 or 31, wherein the notch defines a teardrop-shaped opening in the blade head.

33. A longitudinal axis that bisects the guide bar into a first side portion and a second side portion extends between the distal end and the proximal end of the guide bar, The saw blade cartridge according to any one of claims 30 to 32, wherein the recess is defined at the proximal end of at least one of the first plate, the second plate, or the inner plate and is disposed on one of the first side portion or the second side portion.

34. Each of the first plate, the second plate, or the inner plate includes opposing outer edges, The saw blade cartridge according to any one of claims 30 to 33, wherein the opposing outer edges of each of the first plate, the second plate, and the inner plate are mirror-symmetric to each other.

35. The saw blade cartridge according to any one of claims 30 to 34, wherein at least one of the plates defines a reference feature configured to facilitate determination of the position and / or orientation of the guide bar within the coordinate system of the navigation system.

36. The saw blade cartridge according to claim 35, wherein the reference feature is selected from the group including an optical marking, a recess, or an opening.

37. A surgical saw system, A surgical device including a mount defining a mounting surface, the mount having A first wall and a second wall that extend above the mounting surface and are disposed on both sides of the longitudinal axis of the mount and are tapered with respect to the longitudinal axis of the mount, At least one tab disposed on each of the first wall and the second wall, each tab being disposed above the mounting surface and extending across the entire mounting surface, A surgical device having, A saw blade cartridge removably attachable to the mount of the surgical device, Comprising a guide bar including a distal portion and a proximal portion, the guide bar having A first plate, A second plate, An inner plate partially disposed between the first plate and the second plate, Having, The proximal portions of each of the first plate and the second plate respectively define an outer peripheral edge, A saw blade cartridge in which a part of the proximal portion of the inner plate extends beyond the outer peripheral edge defined by at least one of the proximal portions of the first plate and the second plate. Comprising, The first wall and the second wall respectively engage at least one of the outer peripheral edges of the first plate or the second plate to facilitate alignment of the saw blade cartridge along the longitudinal axis, and each of the at least one tab engages a surface of the part of the proximal portion of the inner plate that extends beyond the outer peripheral edge defined by at least one of the proximal portions of the first plate and the second plate. A system.

38. The mount further comprises a mount mark, The system according to claim 37, wherein the guide bar is provided with bar marks, and the combination of the mount marks and the bar marks is configured to define the plane of the guide bar within the coordinate system of the navigation system.

39. The system according to claim 37, wherein at least one of the plates defines a reference feature configured to facilitate determination of the position and / or orientation of the saw blade cartridge by the navigation system.

40. The system according to claim 39, wherein the reference feature is selected from the group including optical markings, depressions, or openings.

41. The system according to claim 37, wherein the surgical apparatus further comprises a tracking device configured to track the posture of the surgical instrument in use with the navigation system.

42. The system according to claim 41, wherein the surgical apparatus further comprises one or more markers configured to align the surgical apparatus with respect to the tracking device of the surgical apparatus within a known coordinate system defined by the navigation system.

43. A method for verifying the position and / or orientation of a surgical saw blade by a navigation system, the surgical saw blade including a guide bar having an inner plate partially disposed between a first plate and a second plate, wherein the first plate or the second plate includes a plurality of openings providing access to the surface of the inner plate, the method comprising: disposing a distal end of an instrument including a first tracking device within a first opening of the plurality of openings and positioning the instrument to abut against the surface of the inner plate; repositioning the instrument by disposing the distal end of the instrument within a second opening of the plurality of openings and positioning the instrument to abut against the surface of the inner plate; determining the actual position and actual orientation of the surgical saw blade based at least on the positions of the first opening and the second opening identified using the instrument; determining the expected position and expected orientation of the surgical saw blade based on predetermined geometric data corresponding to the relationship between the attachment features of the surgical manipulator on the first plate or the second plate of the surgical saw blade and the positions of the plurality of openings; comparing the predicted positions and orientations of the plurality of openings with the actual positions and orientations of the plurality of openings A method comprising.

44. The method according to claim 43, further comprising removably fixing the surgical saw blade to the mounting feature of the surgical manipulator.

45. The method according to claim 43 or 44, further comprising repositioning the instrument so that the distal end of the instrument contacts a reference feature disposed on at least one of the mounting feature or the surgical manipulator, facilitating determination of the position and orientation of the surgical saw blade relative to the mounting feature or the surgical manipulator.

46. A method of verifying the position and / or orientation of a surgical saw blade within a known coordinate system defined by a navigation system, the surgical saw blade being coupled to a surgical manipulator by a mounting feature and including a guide bar having a plurality of markings on an outer surface, the method comprising: operating the instrument so that the distal end of the instrument including a first tracking device contacts each of the plurality of markings on the outer surface of the guide bar; repositioning the instrument so that the distal end of the instrument contacts one of the plurality of markings on the outer surface of the guide bar; determining the actual position and actual orientation of each of the markings in the known coordinate system based at least on the posture of the instrument when contacting each of the markings; determining the predicted positions and predicted orientations of the markings in the known coordinate system based on predetermined geometric data; comparing the predicted positions and predicted orientations of each of the plurality of markings with the actual positions and actual orientations of each of the plurality of markings; assigning a corrected position based on a deviation between the predicted positions and predicted orientations of each of the plurality of markings based on the predetermined geometric data and the actual position; defining a plane of the surgical saw blade in the known coordinate system based on the corrected position A method comprising.

47. Each of the plurality of markings is disposed on the outer surface of the guide bar such that the plurality of markings depict a part of the outer periphery of the mounting feature of the surgical manipulator on the outer surface of the guide bar. The method according to claim 46, wherein the step of repositioning the distal end of the instrument from the first marking to the second marking further comprises moving the distal end of the instrument along the outer surface of the guide bar from the first marking to the second marking and tracing the part of the outer periphery of the mounting feature on the outer surface of the guide bar.

48. The plurality of markings are connected by a path defined by optical markings on the outer surface of the guide bar. The method according to claim 47, wherein the step of dragging the distal end of the instrument along the outer surface of the guide bar from the first marking to the second marking further comprises dragging the distal end along the outer surface of the guide bar along a defined path.

49. The method according to any one of claims 46 to 48, further comprising the step of removably fixing the surgical saw blade to the mounting feature of the surgical manipulator.

50. The method according to any one of claims 46 to 49, further comprising the step of repositioning the instrument such that the distal end of the instrument contacts a reference feature disposed on at least one of the mounting feature or the surgical manipulator to facilitate determination of the position and orientation of the surgical saw blade relative to the mounting feature or the surgical manipulator.

51. The method according to any one of claims 46 to 50, wherein the step of determining the predicted position and predicted orientation of the first marking and the second marking in the known coordinate system comprises utilizing predetermined geometric data corresponding to the relationship between the mounting feature of the surgical manipulator and the guide bar.

52. A method of operating a saw blade by a navigation system, the method comprising a guide bar having three plates and at least three markers disposed on the guide bar. Attaching the surgical saw blade to a surgical manipulator including a first tracking device. Contacting each of the at least three landmarks on the surgical saw blade with a distal end of an instrument that includes a second tracking device; Tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system when the distal end of the instrument contacts each of the at least three landmarks on the surgical saw blade, and defining an actual position of each of the at least three landmarks relative to a known coordinate system; Performing a mathematical fit of the actual positions of each of the at least three landmarks and predicted positions of each of the at least three landmarks relative to the known coordinate system; Determining a hybrid position within the known coordinate system based on a product of the mathematical fits for each of the at least three landmarks; Defining a plane of the surgical saw blade based on the hybrid positions for each of the at least three landmarks within the known coordinate system A method comprising.

53. Further comprising contacting a reference point on the surgical manipulator with the distal end of the instrument and defining an actual position of the reference point relative to the first tracking device of the surgical manipulator, The step of performing the least squares fit, Including the actual position of the reference point in combination with the predicted positions for each of the at least three landmarks and the actual positions of each of the at least three landmarks when compared to the reference point relative to the first tracking device of the surgical manipulator; Modifying the positions of the at least three landmarks within the known coordinate system based on the product of the least squares fit; The method according to claim 52, further comprising.

54. The at least three landmarks include at least three openings respectively defined in an outer plate of the guide bar so as to provide access to a surface of an inner plate, The step of contacting each of the at least three landmarks on the surgical saw blade includes placing the distal end of the instrument in each of the three openings and contacting the surface of the inner plate at the position of each opening, the method according to claim 52.

55. The method of claim 54, wherein the distal end of the instrument includes a ball-shaped tip sized to fit within the opening defined in the outer plate of the guide bar. **Claim 56** The method of claim 54, wherein the distal end of the instrument includes a tip having a first dimension smaller than a second dimension of each of the openings defined in the outer plate of the guide bar. **Claim 57** further comprising comparing the product of the least squares fit to a target least squares fit, wherein when the deviation between the product of the least squares fit and the target least squares fit exceeds an acceptable margin defined by the navigation system, the surgical manipulator becomes inoperable, as claimed in claim 52. **Claim 58** A method of aligning a saw blade within a known coordinate system of a navigation system, the surgical saw blade including a guide bar having three plates and at least three openings defined in an outer plate of the guide bar to provide access to an inner plate, the method comprising: attaching the surgical saw blade to a surgical manipulator including a first tracking device; operating the instrument such that a distal end of the instrument including a second tracking device passes through each of the at least three openings and contacts the inner plate exposed by each of the openings; tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system when the distal end of the instrument contacts the inner plate through each of the at least three openings in the surgical saw blade to define an actual position of each of the at least three openings relative to the first tracking device of the surgical manipulator; defining an actual position of a portion of the inner plate exposed by each of the at least three openings within the known coordinate system based on the tracked position of the instrument when contacting the inner plate through each of the at least three openings. Comparing the predicted positions of the portions of the inner plate exposed by each of the at least three openings within the known coordinate system with the actual positions of the portions of the inner plate exposed by each of the at least three openings within the known coordinate system; Based on the deviation between the actual position and the predicted position of the portion of the inner plate exposed by each of the at least three openings within the known coordinate system, correcting the position of the portion of the inner plate exposed by each of the at least three openings within the known coordinate system; Defining the plane of the surgical saw blade based on the correction of the position of the portion of the inner plate exposed by each of the at least three openings within the known coordinate system A method comprising.

59. A method of aligning a saw blade within a known coordinate system of a navigation system, the saw blade including a guide bar having three plates and at least three reference features disposed on the guide bar, the method comprising: Attaching the surgical saw blade to a surgical manipulator including a first tracking device; Contacting each of at least three reference features on the surgical saw blade with a distal end of a surgical instrument including a second tracking device; When the distal end of the surgical instrument contacts each of the at least three reference features on the surgical saw blade, tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system to define the actual positions of each of the at least three reference features relative to the first tracking device of the surgical manipulator; Performing a mathematical fit based on the actual positions of each of the at least three reference features and the predicted positions of each of the at least three reference features relative to the known coordinate system; Determining a hybrid position of the at least three reference features within the known coordinate system based on the mathematical fit; Defining the plane of the surgical saw blade based on the hybrid position of the at least three reference features within the known coordinate system A method comprising.

60. The at least three reference features are defined on an outer surface of the guide bar The method of claim 59, wherein the step of contacting each of the at least three reference features on the surgical saw blade with the distal end of the surgical instrument comprises touching the distal end of the surgical instrument against each of the at least three reference features on the outer surface of the guide bar.

61. The at least three reference features are defined on a surface of an inner plate of the guide bar, and an outer plate of the guide bar includes openings corresponding to positions of each of the at least three reference features on the inner plate, each opening terminating at a position of one of each of the at least three reference features on the inner plate to provide access to the reference feature, The method of claim 59, wherein the step of contacting each of the at least three reference features on the surgical saw blade with the distal end of the surgical instrument comprises inserting the distal end of the surgical instrument through each of the openings of the outer plate to contact each of the at least three reference features of the inner plate of the guide bar.

62. A method of controlling a handheld medical robotic system for use with a surgical saw blade, the surgical saw blade including a guide bar having an inner plate partially disposed between a first plate and a second plate, the first plate or the second plate including a plurality of openings providing access to a surface of the inner plate, the method comprising: Aligning the surgical saw blade with a navigation system by operating the instrument to define a plane of the surgical saw blade in a first coordinate system relative to a second tracking device coupled to the handheld medical robotic system by inserting a distal end of the instrument including a first tracking device into each of the plurality of openings to contact the surface of the inner plate at each position of the plurality of openings; Navigating the surgical saw blade based on the position and orientation of the second tracking device; And a method comprising.

63. A method for controlling a handheld medical robotic system for use with a surgical saw blade, the surgical saw blade including two reference features disposed on an outer surface of a guide bar of the surgical saw blade and an optical marking on the surface of the guide bar extending between the two reference features, the method comprising: Aligning the surgical saw blade with a navigation system, using a distal end of an instrument including a first tracking device to contact the surface of the guide bar and tracing the optical marking extending between the two reference features to operate the instrument to define a plane of the surgical saw blade within a first coordinate system with respect to a second tracking device coupled to the handheld medical robotic system; Navigating the surgical saw blade based on the position and orientation of the second tracking device; A method comprising.

64. A surgical saw system, comprising: A surgical device including a mount defining a mounting surface, the mount including: A first wall and a second wall extending above the mounting surface and disposed on both sides of a longitudinal axis of the mount, each of the first wall and the second wall having a proximal portion and a distal portion, the proximal portion being oriented at a first internal taper angle with respect to the longitudinal axis of the mount, the distal portion being oriented at a second internal taper angle with respect to the longitudinal axis of the mount, the second internal taper angle being greater than the first internal taper angle with respect to the longitudinal axis of the mount and not the first taper, the first wall and the second wall; At least one tab disposed on each of the first wall and the second wall, each tab being disposed above the mounting surface and extending across the entire mounting surface; A surgical device comprising; A saw blade cartridge removably attachable to the mount of the surgical device, the guide bar including a distal portion and a proximal portion, the guide bar comprising: A first plate; A second plate; An inner plate partially disposed between the first plate and the second plate; Comprising; A saw blade cartridge comprising a guide bar, wherein one of the first plate and the second plate defines an outer edge of the proximal portion of the guide bar; Comprising; The proximal portions of the first wall and the second wall each engage the outer edge of the proximal portion of the guide bar to facilitate alignment of the saw blade cartridge along the longitudinal axis, the distal portions of the walls are spaced from the outer edge of the proximal portion of the guide bar, A system in which the lower surface of each of the at least one tab is disposed over the entire upper surface of the inner plate. **Claim 65** A surgical saw system, A surgical device including a mount that defines a mounting surface, the mount having a first wall and a second wall that extend above the mounting surface and are disposed on both sides of the longitudinal axis of the mount and are tapered with respect to the longitudinal axis of the mount, at least one tab disposed on each of the first wall and the second wall, each tab being disposed above the mounting surface and extending across the entire mounting surface, A surgical device comprising: A saw blade cartridge removably connectable to the mount of the surgical device, the saw blade cartridge including a guide bar having a distal portion and a proximal portion, a first plate and a second plate, at least one of which defines a first outer edge of the proximal portion of the guide bar, an inner plate partially disposed between the first plate and the second plate and defining a pivoting surface and a second outer edge of a portion of the proximal portion of the guide bar, Comprising: The second outer edge of the inner plate extends beyond the first outer edge defined by the first plate and engages the first wall and the second wall of the surgical device to assist in aligning the saw blade cartridge within the mount of the surgical device. A saw blade cartridge comprising a guide bar configured as such. A system comprising: **Claim 66** A saw blade cartridge for use with a surgical device, a guide bar including a distal portion and a proximal portion, a first plate, a second plate disposed adjacent to the first plate and defining a pivoting surface, A guide bar comprising: a blade extending distally from the distal portion of the guide bar, a blade body including a proximal end and a distal end, a blade head disposed at the distal end of the blade body and having teeth formed thereon, Comprising: A blade, wherein the proximal end of the blade body abuts the pivoting surface, Comprising: the proximal portion defines a proximal end, the first plate defines a first outer edge, the second plate defines a second outer edge that extends beyond the first outer edge defined by the first plate, the second outer edge being tapered outwardly and moving distally from the proximal end of the proximal portion toward the distal end of the proximal portion to assist in aligning the saw blade cartridge with the surgical device, a saw blade cartridge.

67. A saw blade cartridge for use with a surgical device, a guide bar including a distal portion and a proximal portion, a first plate defining a first outer edge of the proximal portion, a second plate disposed adjacent to the first plate and defining a second outer edge of the proximal portion of the pivot surface and the guide bar, comprising the second outer edge extends beyond the first outer edge defined by the first plate and is configured to engage the surgical device to assist in aligning the saw blade cartridge with the surgical device, a guide bar; a blade extending distally from the distal portion of the guide bar and comprising a blade body including a proximal end configured to abut the pivot surface, a blade comprising a saw blade cartridge.

68. The saw blade cartridge according to claim 67, wherein the guide bar further comprises a third plate, and the second plate is at least partially disposed between the first plate and the third plate.

69. The saw blade cartridge according to claim 67 or 68, wherein the first plate defines a reference feature configured to facilitate determination of the position and / or orientation of the surgical blade by a navigation system.

70. The saw blade cartridge according to claim 68, wherein one of the first plate or the third plate defines a reference feature configured to facilitate determination of the position and / or orientation of the surgical blade by a navigation system.

71. The first plate or the third plate each define at least one reference feature, and the combination of the reference features is configured to facilitate determination of the position and / or orientation of the surgical blade within a known coordinate system of a navigation system. The saw blade cartridge according to claim 68.

72. The reference features are arranged on each of the first plate and the third plate such that the reference features of the first plate and the third plate are mirror images of each other. The saw blade cartridge according to claim 71.

73. The reference features are arranged on each of the first plate and the third plate so as to be concentrically aligned with each other. The saw blade cartridge according to claim 71.

74. The reference feature is defined by an opening having a first dimension, and the first dimension is smaller than a second dimension of the tip of a surgical instrument associated with the navigation system for engaging the reference feature, and is configured to facilitate determination of the position and / or orientation of the surgical blade with respect to the navigation system. The saw blade cartridge according to claim 69 or 70.

75. At least one of the second plate or the blade body further comprises a reference feature configured to facilitate determination of the position and / or orientation of the surgical blade by a navigation system. The first plate is shaped to provide access to the reference feature of at least one of the second plate or the blade body. The saw blade cartridge according to claim 67 or 68.

76. The reference feature is selected from the group including an optical marking, a depression, or an opening. The saw blade cartridge according to claim 69 or 75.

77. A saw blade cartridge for use with a surgical device guided by a navigation system, A guide bar including a distal portion and a proximal portion, A first plate defining a first opening, A second plate defining a second opening, An inner plate partially disposed between the first plate and the second plate and defining a pivotal surface, Comprising A guide bar, wherein the first opening and the second opening are configured to facilitate determination of the position and / or orientation of the guide bar by a navigation system. A blade comprising a blade body extending distally from the distal portion of the guide bar and including a proximal end configured to abut against the pivoting surface. Comprising: The proximal portion defines a proximal end. A saw blade cartridge, wherein the first plate and the second plate are arranged such that the first opening and the second opening are concentrically aligned. **Claim 78** The saw blade cartridge according to claim 77, wherein the first opening and the second opening are defined on both sides of the inner plate. **Claim 79** The saw blade cartridge according to claim 77 or 78, wherein the first opening and the second opening are defined on both sides of the guide bar. **Claim 80** The saw blade cartridge according to any one of claims 77 to 79, wherein each of the openings defines a reference feature distinguishable by the navigation system, facilitating determination of the position and / or orientation of the surgical blade within a known coordinate system. **Claim 81** The saw blade cartridge according to any one of claims 77 to 80, wherein each of the openings further comprises a marking for identifying the opening as a reference feature, the marking including at least one of a laser marking, a notch, a color, an engraving, a symbol, or a bevel. **Claim 82** The guide bar includes a longitudinal axis extending between the distal portion and the proximal portion of the guide bar and bisecting the guide bar. The saw blade cartridge according to any one of claims 77 to 81, wherein the first plate and the second plate each define a plurality of openings, and at least one of the plurality of openings defined by each of the first plate and the second plate is disposed on both sides of the longitudinal axis of the guide bar. **Claim 83** The guide bar includes a longitudinal axis extending between the distal portion and the proximal portion of the guide bar and bisecting the guide bar. The saw blade cartridge according to any one of claims 77 to 81, wherein the first opening and the second opening are each disposed on the longitudinal axis of each plate of the guide bar.

84. A saw blade cartridge for use with a surgical instrument including a tracker identifiable by a navigation system / associated with a navigation system, A guide bar having a distal portion and a proximal portion, A first plate defining a first reference feature at the distal portion and a second reference feature at the proximal portion, A second plate defining a third reference feature at the distal portion and a fourth reference feature at the proximal portion, An inner plate at least partially disposed between the first plate and the second plate, Comprising, A guide bar, wherein the combination of the reference features can be used for aligning the saw blade cartridge within a known coordinate system defined by the navigation system with respect to the tracker of the surgical instrument, A blade at least partially disposed between the first plate and the second plate, A blade body including a proximal end and a distal end, A blade head disposed at the distal end of the blade body and having teeth formed thereon, Comprising, a blade Comprising, a saw blade cartridge.

85. The saw blade cartridge according to claim 84, wherein the first reference feature and the third reference feature are disposed at the distal portion of the guide bar, and the second reference feature and the fourth reference feature are disposed at the proximal portion of the guide bar.

86. The guide bar includes a longitudinal axis extending between the distal portion and the proximal portion of the guide bar and bisecting the guide bar, The first reference feature and the second reference feature of the first plate are disposed on both sides of the longitudinal axis, The saw blade cartridge according to claim 84, wherein the third reference feature and the fourth reference feature of the second plate are disposed on both sides of the longitudinal axis.

87. The guide bar includes a longitudinal axis extending between the distal portion and the proximal portion of the guide bar and bisecting the guide bar, At least one of the first reference feature and the second reference feature of the first plate is disposed on the longitudinal axis. The saw blade cartridge according to claim 84, wherein at least one of the third reference feature and the fourth reference feature of the second plate is disposed on the longitudinal axis. **Claim 88** A surgical saw assembly for use with a navigation system, comprising: A surgical instrument / device including instrument reference features; A tracker disposed on the surgical instrument and identifiable by and / or associated with the navigation system; A saw blade cartridge removably attachable to the surgical device; A guide bar having a distal portion and a proximal portion; A first plate defining a first reference feature at the distal portion and a second reference feature at the proximal portion; A second plate defining a third reference feature at the distal portion and a fourth reference feature at the proximal portion; An inner plate at least partially disposed between the first plate and the second plate and defining a pivot surface; Comprising: A guide bar, wherein the combination of the reference features can be used to facilitate alignment of the saw blade cartridge within a known coordinate system defined by the navigation system relative to the tracker of the surgical device; A blade extending from the distal portion of the guide bar; A saw blade cartridge comprising: A surgical saw assembly comprising: **Claim 89** The first plate comprises a second reference feature; The surgical saw assembly according to claim 88, wherein the second plate comprises a fourth reference feature. **Claim 90** The surgical saw assembly according to claim 89, wherein the first reference feature and the third reference feature are disposed at the distal portion of the guide bar, and the second reference feature and the fourth reference feature are disposed at the proximal portion of the guide bar. **Claim 91** The guide bar includes a longitudinal axis extending between the distal portion and the proximal portion of the guide bar and bisecting the guide bar; The first reference feature and the second reference feature of the first plate are disposed on opposite sides of the longitudinal axis. The surgical saw assembly according to claim 89, wherein the third reference feature and the fourth reference feature of the second plate are disposed on both sides of the longitudinal axis.

92. The guide bar includes a longitudinal axis that extends between the distal portion and the proximal portion of the guide bar and bisects the guide bar. At least one of the first reference feature and the second reference feature of the first plate is disposed on the longitudinal axis. The surgical saw assembly according to claim 89, wherein at least one of the third reference feature and the fourth reference feature of the second plate is disposed on the longitudinal axis.

93. A method of aligning a saw blade within a known coordinate system of a navigation system, the surgical saw blade including a guide bar having three plates, and at least three reference features defined on the guide bar, the method comprising: Attaching the surgical saw blade to a surgical manipulator including a first tracking device. Contacting each of the at least three reference features on the surgical saw blade with a distal end of a surgical instrument including a second tracking device. Tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system when the distal end of the surgical instrument contacts each of the at least three reference features on the surgical saw blade, and defining the actual positions of each of the at least three reference features relative to the first tracking device of the surgical manipulator. Defining a plane of the surgical saw blade based on the actual positions of the at least three reference features within the known coordinate system. A method comprising:

94. The method according to claim 93, further comprising controlling the surgical manipulator based on the defined plane and a target cutting plane.

95. The method according to claim 93 or 94, wherein the defined plane is defined without prior information of an expected position of the blade relative to the surgical manipulator.

96. A method of aligning a saw blade within a known coordinate system of a navigation system, comprising: Attaching the surgical saw blade to a surgical manipulator including a first tracking device. Contacting each of at least two fiducial features on the first surface of the surgical saw blade with a distal end of a surgical instrument that includes a second tracking device; Contacting each of at least two fiducial features on the second surface of the surgical saw blade with the distal end of the surgical instrument; Tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system when the distal end of the surgical instrument contacts each of the fiducial features on the first surface and the second surface of the surgical saw blade, and defining actual positions of each of the fiducial features of the first surface and the second surface relative to the first tracking device of the surgical manipulator; Comparing the actual positions of each of the fiducial features in the known coordinate system and the position of the manipulator fiducial feature to confirm whether the surgical saw blade is properly attached to the surgical manipulator; A method comprising.

97. The step of contacting each of the at least two fiducial features on the first surface includes contacting a first fiducial feature disposed at a proximal portion of the first surface and contacting a second fiducial feature disposed at a distal portion of the first surface, The step of contacting each of the at least two fiducial features on the second surface includes contacting a third fiducial feature disposed at a proximal portion of the second surface and contacting a fourth fiducial feature disposed at a distal portion of the second surface, The method according to claim 96.

98. The surgical saw blade includes a distal portion and a proximal portion, extends between the distal portion and the proximal portion, and has a longitudinal axis that bisects the surgical saw blade, The step of contacting each of the at least two fiducial features on the first surface includes contacting a first fiducial feature disposed at a first portion of the first surface and contacting a second fiducial feature disposed at a second portion of the first surface such that the first portion and the second portion of the first surface are located on opposite sides of the longitudinal axis; The step of contacting each of the at least two fiducial features on the second surface includes contacting a third fiducial feature disposed in the third portion such that a third portion of the second surface and a fourth portion of the second surface are on opposite sides of the longitudinal axis, and contacting a fourth fiducial feature disposed in the fourth portion, the method of claim 96.

99. Contacting a manipulator fiducial feature on the surgical manipulator with the distal end of the surgical instrument; Tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system when the distal end of the surgical instrument contacts the manipulator fiducial feature to define an actual position of the manipulator fiducial feature in the known coordinate system relative to the first tracking device of the surgical manipulator; The method according to any one of claims 96 to 98, further comprising:

100. Comparing the actual position of the manipulator fiducial feature to the actual positions of the fiducial features of the first surface and the second surface in the known coordinate system to define a deviation between the actual position of the manipulator fiducial feature and the actual positions of the fiducial features of the first surface and the second surface respectively; Determining whether the surgical saw blade is properly attached to the surgical manipulator based on the defined deviation being within an acceptable threshold / range based on the comparison of the actual position of the manipulator fiducial feature to the actual positions of the fiducial features of the first surface and the second surface; The method according to claim 99, further comprising:

101. The method according to any one of claims 96 to 100, further comprising defining a tool center point of the surgical saw blade based on the actual positions of the fiducial features in the known coordinate system.

102. The method according to claim 101, further comprising navigating the surgical saw blade by the navigation system based on the defined tool center point of the surgical saw blade.

103. The method according to any one of claims 96 to 100, further comprising the step of defining a plane of the surgical saw blade based on the actual positions of the respective reference features in the known coordinate system.

104. The method according to any one of claims 96 to 100, further comprising the step of defining a hybrid position of the manipulator reference feature in the known coordinate system based on the mathematical fit of the actual position of the reference feature of the surgical saw blade and the manipulator reference point, The step of defining the hybrid position of the manipulator reference feature in the known coordinate system based on the mathematical fit is such that the hybrid position of the manipulator reference feature differs from the actual position of the manipulator reference feature by only one degree of freedom.

105. The method according to claim 104, wherein the one degree of freedom is along the longitudinal axis of the surgical saw blade.

106. A method of aligning a saw blade in a known coordinate system of a navigation system, comprising: attaching a surgical saw blade cartridge to a surgical manipulator, the surgical saw blade cartridge including a guide bar having a first plate disposed adjacent to a second plate, and a blade at least partially disposed between the first plate and the second plate and extending from a distal end of the guide bar, the surgical manipulator including a first tracking device; contacting at least two respective reference features on the first plate of the guide bar with a distal end of a surgical instrument including a second tracking device; contacting at least two respective reference features on the second plate of the guide bar with the distal end of the surgical instrument, wherein each of the reference features of the first plate is concentric with one of the reference features of the second plate. When the distal end of the surgical instrument contacts each of the reference features on the first plate and the second plate of the surgical saw blade cartridge, tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system, and defining the actual positions of each of the reference features of the first plate and the second plate with respect to the first tracking device of the surgical manipulator; Determining the thickness of the cartridge based on the actual positions of the reference features on the first plate and the second plate; Providing an indication to the user based on the determined thickness of the cartridge A method comprising.

107. The step of contacting each of the at least two reference features on the first plate includes contacting a first reference feature disposed at a proximal portion of the first plate and contacting a second reference feature disposed at a distal portion of the first plate, The method according to claim 106, wherein the step of contacting each of the at least two reference features on the second plate includes contacting a third reference feature disposed at a proximal portion of the second plate and contacting a fourth reference feature disposed at a distal portion of the second plate.

108. The method according to claim 107, wherein the step of determining the thickness of the surgical blade further includes defining a first blade thickness based on a comparison of the positions of the first reference feature of the first plate and the third reference feature of the second plate.

109. The method according to claim 108, wherein the step of determining the thickness of the surgical blade further includes defining a second blade thickness based on a comparison of the positions of the second reference feature of the first plate and the fourth reference feature of the second plate.

110. Calculating a deviation between the first blade thickness and the second blade thickness; Permitting alignment of the surgical blade within the known coordinate system of the navigation system based on the deviation between the first blade thickness and the second blade thickness being within an acceptable threshold / range. The method according to claim 109, further comprising **Claim 111** The method according to claim 110, wherein the deviation between the first blade thickness and the second blade thickness indicates deflection of the distal portion of the first plate and / or the second plate when contacting the second reference feature or the fourth reference feature. **Claim 112** The method according to any one of claims 106 to 111, wherein the step of giving the indication includes at least one of a visual cue, an auditory cue, and / or a tactile cue to the user. **Claim 113** The method according to any one of claims 106 to 112, wherein the step of giving the indication indicates to the user that the determined thickness is outside a specified threshold range or exceeds a specified threshold. **Claim 114** The method according to any one of claims 106 to 112, wherein the step of giving the indication indicates that the user needs to replace the surgical saw blade and / or realign the surgical saw blade with respect to the navigation system. **Claim 115** The surgical saw blade includes a distal portion and a proximal portion, and has a longitudinal axis extending between the distal portion and the proximal portion and bisecting the surgical saw blade. The step of contacting each of the at least two reference features on the first plate includes contacting a first reference feature disposed on the first portion of the first plate and a second reference feature disposed on the second portion of the first plate such that the first portion and the second portion of the first plate are on opposite sides of the longitudinal axis. The step of contacting each of the at least two reference features on the second plate includes contacting a third reference feature disposed on the third portion of the second plate and a fourth reference feature disposed on the fourth portion of the second plate such that the third portion and the fourth portion of the second plate are on opposite sides of the longitudinal axis. The method according to claim 106. **Claim 116** Contacting a manipulator reference feature on the surgical manipulator with the distal end of the surgical instrument. When the distal end of the surgical instrument contacts the manipulator reference feature, tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system to define an actual position of the manipulator reference feature in the known coordinate system with respect to the first tracking device of the surgical manipulator; The method according to any one of claims 106 to 115, further comprising. **Claim 117** Comparing the actual position of the manipulator reference feature in the known coordinate system with respect to the actual positions of the reference features of the first plate and the second plate in the known coordinate system to determine whether the surgical saw blade is properly attached to the surgical manipulator. The method according to claim 116, further comprising. **Claim 118** Defining a deviation by comparing the actual position of the manipulator reference feature in the known coordinate system and the actual positions of the reference features of the first plate and the second plate in the known coordinate system with respect to the predicted position of the manipulator reference feature and the predicted positions of the reference features of the first plate and the second plate; Determining whether the surgical saw blade is properly attached to the surgical manipulator based on the deviation and a deviation threshold; The method according to claim 116, further comprising. **Claim 119** The method according to any one of claims 106 to 118, further comprising controlling a plurality of actuators of the surgical manipulator based on the defined plane and a target cutting plane. **Claim 120** A method of aligning a saw blade in a known coordinate system of a navigation system, comprising: Attaching a surgical saw blade to a surgical manipulator including a first tracking device; Contacting at least two reference features on a first surface of the surgical saw blade with a distal end of a surgical instrument including a second tracking device; Contacting at least two reference features on a second surface of the surgical saw blade with the distal end of the surgical instrument; Contacting at least one reference feature on the surgical manipulator; When the distal end of the surgical instrument contacts each of the reference features on the surgical saw blade and the surgical manipulator, tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system to define the actual positions of the reference features of the surgical saw blade relative to the reference feature of the surgical manipulator; Defining a hybrid position of each of the at least one reference feature of the surgical manipulator by performing a mathematical fit between the actual positions of the reference features of the surgical saw blade and the at least one reference feature of the surgical manipulator; A method comprising.

121. The step of defining the hybrid position of the at least one reference feature of the surgical manipulator in the known coordinate system based on the mathematical fit is such that the hybrid position of each of the reference features differs from the actual position by only one degree of freedom, the method according to claim 120.

122. The step of defining the hybrid position of the at least one reference feature of the surgical manipulator in the known coordinate system based on the mathematical fit is to move the actual position of each of the at least one reference feature of the surgical manipulator by only one degree of freedom, the method according to claim 120.

123. The method according to claim 121 or 122, wherein the one degree of freedom is along the longitudinal axis of the surgical saw blade.

124. Comparing the actual position of the at least one reference feature of the manipulator with the actual position of each of the reference features of the surgical saw blade; Determining whether the surgical saw blade is properly attached to the surgical manipulator based on the deviation between the actual position of the at least one reference feature of the surgical manipulator and the actual position of each of the reference features of the surgical saw blade being within an allowable threshold / range; The method according to any one of claims 120 to 123, further comprising.

125. Based on the deviation between the actual position of the at least one reference feature of the manipulator and the actual position of each of the reference features of the surgical saw blade being within an allowable threshold / range, further including the step of rejecting the alignment of the surgical saw blade within the known coordinate system of the navigation system, the method according to any one of claims 120 to 123.

126. The method according to claim 124 or 125, wherein the allowable threshold of the deviation between the actual position of the at least one reference feature of the manipulator and the actual position of each of the reference features of the surgical saw blade is plus or minus 1 millimeter (±1 mm).

127. Comparing the hybrid position of the at least one reference feature of the manipulator with the actual position of each of the reference features of the surgical saw blade; Based on the deviation between the hybrid position of the at least one reference feature of the manipulator and the actual position of each of the reference features of the surgical saw blade being within an allowable threshold / range, determining whether the surgical saw blade is properly attached to the surgical manipulator; The method according to any one of claims 120 to 123, further including this.

128. Based on the deviation between the hybrid position of the at least one reference feature of the manipulator and the actual position of each of the reference features of the surgical saw blade being within an allowable threshold / range, further including the step of rejecting the alignment of the surgical saw blade within the known coordinate system of the navigation system, the method according to any one of claims 120 to 123.

129. The method according to claim 127 or 128, wherein the allowable threshold of the deviation between the hybrid position of the at least one reference feature of the manipulator and the actual position of each of the reference features of the surgical saw blade is plus or minus 1 millimeter (±1 mm).

130. A method of aligning a surgical saw blade within a known coordinate system of a navigation system, comprising: Attaching the surgical saw blade to a surgical manipulator including a first tracking device; Contacting at least two reference features on the first surface of the surgical saw blade with the distal end of the surgical instrument including the second tracking device, respectively; Contacting at least two reference features on the second surface of the surgical saw blade with the distal end of the surgical instrument, respectively; When the distal end of the surgical instrument contacts the reference features on the first surface and the second surface of the surgical saw blade, respectively, tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system, and defining the actual positions of the reference features of the first surface and the second surface with respect to the first tracking device of the surgical manipulator; Defining the position and / or orientation of the surgical saw blade in the known coordinate system with one or more degrees of freedom based on a mathematical fit of the positions of the at least two reference features on the first surface and the second surface, respectively; A method comprising.

131. Contacting a manipulator reference feature defined on the surgical manipulator with the distal end of the surgical instrument; Defining a hybrid position of the manipulator reference feature in the known coordinate system based on a comparison of the actual positions of the reference features of the first surface and the second surface with respect to the manipulator reference feature; Further comprising, The method according to claim 130, wherein a tool center point is further defined based on a mathematical fit of the positions of the at least two reference features on the first surface and the second surface, respectively, and the hybrid position of the manipulator reference feature.

132. The method according to claim 130 or 131, wherein the step of defining the position and / or orientation of the surgical saw blade in the known coordinate system with one or more degrees of freedom includes defining the position and / or orientation of the surgical saw blade in the known coordinate system with up to six degrees of freedom.

133. A method of aligning a surgical saw assembly in a known coordinate system of a navigation system, comprising: Attaching a surgical saw blade to a surgical manipulator including a first tracking device; Contacting at least two reference features on the first surface of the surgical saw blade with the distal end of the surgical instrument including the second tracking device, respectively; Contacting at least two reference features on the second surface of the surgical saw blade with the distal end of the surgical instrument, respectively; Contacting a manipulator reference feature defined on the surgical manipulator with the distal end of the surgical instrument; When the distal end of the surgical instrument contacts the reference features on the first surface and the second surface of the surgical saw blade, respectively, tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system, and defining the actual positions of the reference features of the first surface and the second surface and the manipulator reference feature with respect to the first tracking device of the surgical manipulator; Defining a hybrid position of the manipulator reference feature in the known coordinate system based on a comparison of the actual positions of the reference features of the first surface and the second surface with respect to the manipulator reference feature; Defining the position and / or orientation of the surgical saw assembly in the known coordinate system with at least one degree of freedom based on a mathematical fit of the positions of the at least two reference features of the first surface and the second surface and the hybrid position of the manipulator reference feature; A method comprising.

134. The method according to claim 133, wherein the step of defining the position and / or orientation of the surgical saw blade in the known coordinate system with one or more degrees of freedom includes defining the position and / or orientation of the surgical saw blade in the known coordinate system with up to six degrees of freedom.

135. A method of aligning a saw assembly in a known coordinate system of a navigation system, comprising: Attaching a surgical saw blade to a surgical manipulator including a first tracking device; Contacting at least two reference features on the first surface of the surgical saw blade with the distal end of the surgical instrument including the second tracking device, respectively; Contacting at least two reference features on the second surface of the surgical saw blade with the distal end of the surgical instrument, respectively; Contacting a manipulator reference feature defined on the surgical manipulator with the distal end of the surgical instrument; When the distal end of the surgical instrument contacts each of the reference features on the first surface and the second surface of the surgical saw blade, tracking the positions of the first tracking device and the second tracking device by a localizer of the navigation system, and defining the actual positions of the reference features of the first surface and the second surface and the manipulator reference feature with respect to the first tracking device of the surgical manipulator; Applying a first mathematical fit to each other to the actual positions of the reference features of the first surface and the second surface and the manipulator reference feature; Defining a hybrid position of the manipulator reference feature based on the first mathematical fit; Applying a second mathematical fit to each other to the actual positions of the reference features of the first surface and the second surface and the hybrid position of the manipulator reference feature; Defining the position and / or orientation of the surgical saw assembly in the known coordinate system in one or more degrees of freedom based on the second mathematical fit A method comprising.

136. The method according to claim 135, wherein the step of defining the position and / or orientation in one or more degrees of freedom includes defining the position and / or orientation in up to six degrees of freedom.

137. A method for verifying the attachment of a surgical saw blade to a surgical manipulator, comprising: Attaching the surgical saw blade to the surgical manipulator including a first tracking device; Contacting each of at least two reference features on a first surface of the surgical saw blade with a distal end of a surgical instrument including a second tracking device; Contacting a manipulator reference feature defined on the surgical manipulator with the distal end of the surgical instrument; Applying a mathematical fit to each other to the actual positions of the reference feature of the first surface and the manipulator reference feature; A step of comparing the output of the mathematical fit with a threshold value, wherein the output of the mathematical fit with respect to the threshold value indicates whether the surgical saw blade is properly attached to the surgical manipulator, and the step A method comprising: **Claim 138** Further comprising the step of contacting each of at least two reference features on a second surface of the surgical saw blade with the distal end of the surgical instrument, The method according to claim 137, wherein the step of applying the mathematical fit includes applying a mathematical fit to the actual positions of the reference features on the second surface relative to the reference features on the first surface and the manipulator reference features to each other. **Claim 139** A method for verifying the alignment of a surgical saw blade within a known coordinate system of a navigation system, comprising: Attaching the surgical saw blade to a surgical manipulator including a first tracking device; Contacting a first reference feature disposed proximally of a first plate of the surgical saw blade and a second reference feature disposed distally of the first plate with a distal end of a surgical instrument including a second tracking device; Contacting a third reference feature disposed proximally of a second plate of the surgical saw blade and a fourth reference feature disposed distally of the second plate with the distal end of the surgical instrument; Defining a first blade thickness based on a comparison of the positions of the first reference feature of the first plate and the third reference feature of the second plate; Defining a second blade thickness based on a comparison of the positions of the second reference feature of the first plate and the fourth reference feature of the second plate; Calculating a deviation between the first blade thickness and the second blade thickness; Including The method, wherein the deviation between the first blade thickness and the second blade thickness indicates a deflection of the distal portion of the first plate and / or the second plate when contacting the second reference feature or the fourth reference feature.

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